DOWNLOAD! (13 MB) 1993 - 2000 Ford Mondeo Service Manual / Repair Manual / Workshop Manual - Covering All 4 Cylinder Petrol Engines - 1597 cc 1796 cc 1988 cc (PDF Format) !!

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Introduction
belt grabbers" and pre-tensioners, and an airbag fitted to the steering wheel. Vehicle security is enhanced, with an in-built alarm system and engine immobiliser being fitted as standard, as well as double-locking doors with shielded locks, and security-coded audio equipment. The four-cylinder petrol engine is a new design, available in 1.6, 1.8 and 2.0 litre capacities. It is controlled by a sophisticated engine management system, which combines multi-point sequential fuel injection and distributorless ignition systems with evaporative emissions control, exhaust gas recirculation and a three-way regulated catalytic converter (with a pulse-air system for rapid warm-up) to ensure that the vehicle complies with the most stringent of the emissions control standards currently in force, and yet provides the levels of performance and fuel economy expected. The transversely-mounted engine drives the front roadwheels through either a fivespeed manual transmission with a cableoperated clutch, or through an electronic
allycontrolled four-speed automatic transmission. The fully-independent suspension is by MacPherson strut on all four roadwheels, located by transverse lower arms at the front, and by transverse and trailing arms at the rear; anti-roll bars are fitted at front and rear. The Estate rear suspension is of a different design, to give maximum loadspace inside the vehicle, with self-levelling suspension units available as an option. On some models, the suspension is electronically-controlled through the Adaptive Damping System. The steering is power-assisted, the pump being belt-driven from the engine, and the rack-and-pinion steering gear mounted behind the engine. The vacuum servo-assisted brakes are disc at the front, with drums at the rear on most models; disc rear brakes and an electronically-controlled Anti-lock Braking System (ABS) are available on some models, with a Traction Control System (TCS) available as a further option where ABS is fitted.

Introduction to the Ford Mondeo
Introduced in March 1993, the Ford Mondeo models are available in four-door Saloon, five-door Hatchback and five-door Estate configurations. All feature a high standard of equipment, with driver/passenger safety in accidents being a particularly high design priority; all models are fitted with features such as side impact bars in all doors, "anti-submarine" seats combined with "seat

Ford Mondeo 2.0 Ghia Saloon

Acknowledgements
Thanks are due to Champion Spark Plug, who supplied the illustrations showing spark plug conditions. Certain other illustrations are the copyright of the Ford Motor Company, and are used with their permission. Thanks are also due to Sykes-Pickavant Limited, who provided some of the workshop tools, and to all those people at Sparkford who helped in the production of this manual.

Project vehicles
The main project vehicle used in the preparation of this manual, and appearing in many of the photographic sequences, was a 1993-model Ford Mondeo 2.0 Si Hatchback. Additional work was carried out and photographed on a 1993-model 2.0 Si Saloon and a 1993-model 2.0 Ghia Estate (with automatic transmission). Ford Mondeo 1.8 GLX Estate

Safety First!
Working on your car can be dangerous. This page shows just some of the potential risks and hazards, with the aim of creating a safety-conscious attitude.

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General hazards
Scalding
· Don't remove the radiator or expansion tank cap while the engine is hot. · Engine oil, automatic transmission fluid or power steering fluid may also be dangerously hot if the engine has recently been running.

· Mains voltage is also dangerous. Make sure that any mains-operated equipment is correctly earthed. Mains power points should be protected by a residual current device (RCD) circuit breaker.

Special hazards
Hydrofluoric acid
· This extremely corrosive acid is formed when certain types of synthetic rubber, found in some O-rings, oil seals, fuel hoses etc, are exposed to temperatures above 4000C. The rubber changes into a charred or sticky substance containing the acid. Once formed, the acid remains dangerous for years. If it gets onto the skin, it may be necessary to amputate the limb concerned. · When dealing with a vehicle which has suffered a fire, or with components salvaged from such a vehicle, wear protective gloves and discard them after use.

Fume or gas intoxication
· Exhaust fumes are poisonous; they often contain carbon monoxide, which is rapidly fatal if inhaled. Never run the engine in a confined space such as a garage with the doors shut. · Fuel vapour is also poisonous, as are the vapours from some cleaning solvents and paint thinners.

Burning
· Beware of burns from the exhaust system and from any part of the engine. Brake discs and drums can also be extremely hot immediately after use.

The battery
· Batteries contain sulphuric acid, which attacks clothing, eyes and skin. Take care when topping-up or carrying the battery. · The hydrogen gas given off by the battery is highly explosive. Never cause a spark or allow a naked light nearby. Be careful when connecting and disconnecting battery chargers or jump leads.

Crushing
· When working under or near a raised vehicle, always supplement the jack with axle stands, or use drive-on ramps. Never venture under a car which is only supported by a jack. · Take care if loosening or tightening hightorque nuts when the vehicle is on stands. Initial loosening and final tightening should be done with the wheels on the ground.

Poisonous or irritant substances
· Avoid skin contact with battery acid and with any fuel, fluid or lubricant, especially antifreeze, brake hydraulic fluid and Diesel fuel. Don't syphon them by mouth. If such a substance is swallowed or gets into the eyes, seek medical advice. · Prolonged contact with used engine oil can cause skin cancer. Wear gloves or use a barrier cream if necessary. Change out of oilsoaked clothes and do not keep oily rags in your pocket. · Air conditioning refrigerant forms a poisonous gas if exposed to a naked flame (including a cigarette). It can also cause skin burns on contact.

Air bags
· Air bags can cause injury if they go off accidentally. Take care when removing the steering wheel and/or facia. Special storage instructions may apply.

Diesel injection equipment
· Diesel injection pumps supply fuel at very high pressure. Take care when working on the fuel injectors and fuel pipes. Warning: Never expose the hands, face or any other part of the body to injector spray; the fuel can penetrate the skin with potentially fatal results.

Fire
· Fuel is highly flammable; fuel vapour is explosive. · Don't let fuel spill onto a hot engine. · Do not smoke or allow naked lights (including pilot lights) anywhere near a vehicle being worked on. Also beware of creating sparks (electrically or by use of tools). · Fuel vapour is heavier than air, so don't work on the fuel system with the vehicle over an inspection pit. · Another cause of fire is an electrical overload or short-circuit. Take care when repairing or modifying the vehicle wiring. · Keep a fire extinguisher handy, of a type suitable for use on fuel and electrical fires.

Asbestos
· Asbestos dust can cause cancer if inhaled or swallowed. Asbestos may be found in gaskets and in brake and clutch linings. When dealing with such components it is safest to assume that they contain asbestos.

Remember...
DO
· Do use eye protection when using power tools, and when working under the vehicle. · Do wear gloves or use barrier cream to protect your hands when necessary. · Do get someone to check periodically that all is well when working alone on the vehicle. · Do keep loose clothing and long hair well out of the way of moving mechanical parts. · Do remove rings, wristwatch etc, before working on the vehicle ­ especially the electrical system. · Do ensure that any lifting or jacking equipment has a safe working load rating adequate for the job.

A few tips
DON'T
· Don't attempt to lift a heavy component which may be beyond your capability ­ get assistance. · Don't rush to finish a job, or take unverified short cuts. · Don't use ill-fitting tools which may slip and cause injury. · Don't leave tools or parts lying around where someone can trip over them. Mop up oil and fuel spills at once. · Don't allow children or pets to play in or near a vehicle being worked on.

Electric shock
· Ignition HT voltage can be dangerous, especially to people with heart problems or a pacemaker. Don't work on or near the ignition system with the engine running or the ignition switched on.

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General Dimensions & Weights

Dimensions
Overall length: Saloon, Hatchback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Estate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overall width - including mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overall height - at kerb weight: Saloon, Hatchback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Estate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front track - all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear track: Saloon, Hatchback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Estate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turning circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4481 mm 4631 mm 1925 mm 1403 1416 2704 1503 to 1435 mm to 1501 mm mm mm

1486 to 1487 mm 1504 mm 10.9 m

Weights
Kerb weight: 1.6 Saloon, Hatchback models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 Estate models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 Saloon, Hatchback models: Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 Estate models: Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 Saloon, Hatchback models: Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 Estate models: Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum gross vehicle weight: Sal
oon, Hatchback: 1.6 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 Saloon models, automatic transmission . . . . . . . . . . . . . . . . . 2.0 models, automatic transmission . . . . . . . . . . . . . . . . . . . . . . . All others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Estate: 1.6 models, 2.0 models with manual transmission . . . . . . . . . . . . All others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum roof rack load: Estate models with integral roof rack . . . . . . . . . . . . . . . . . . . . . . . . All others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum towing weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trailer nose weight limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1215 to 1250 kg 1265 to 1275 kg 1225 to 1260 kg 1260 to 1280 kg 1275 to 1285 kg
1305 kg 1250 to 1310 kg 1285 to 1340 kg 1295 to 1335 kg 1330 to 1415 kg

1725 kg 1750 kg 1800 kg 1775 kg 1900 kg 1925 kg 100 kg 75 kg 1500 kg 75 kg