Target Audience:
Professional technicians and Do-It-Yourself (DIY) mechanics with basic electrical and mechanical knowledge.
Comparison To Paper Manuals:
Functionally equivalent to paper manuals, offering the same detailed content but with the advantage of instant access and digital portability.
Distinctive Advantages:
Instant download, comprehensive coverage, step-by-step instructions, critical specifications, illustrations (implied from description).
Manual Goal:
To guide users through maintenance and repair procedures, imparting factory-trained technician knowledge for informed decision-making.
Years Covered:
1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000
Estimated Page Count:
Varies (typically 500-1000+ pages for comprehensive factory-level manuals, but specific for this PDF is not stated, assume comprehensive)
Type:
Repair Service Manual
Powertrain:
Engine Mechanical, Fuel System, Ignition System, Lubrication System, Cooling System, Exhaust System, Engine Management (ECU Diagnostics)
Drivetrain:
Manual Transmission, Automatic Transmission, Clutch System, Driveshafts, Differentials, CV Joints
Chassis:
Suspension (Front & Rear), Steering System, Brakes (Hydraulic & Parking), Wheels & Tires
Body:
Body & Frame, Exterior Trim, Interior Trim, Doors, Windows, Seats, HVAC System, Body Electrical (Lighting, Wipers, Horn)
Electrical:
Wiring Diagrams, Battery, Starting System, Charging System, Fuses & Relays, Instrumentation, Audio System, Power Accessories
Engine Management:
On-Board Diagnostics (OBD-II) system, sensor data, actuator testing, ECU reset procedures.
HVAC:
Refrigerant charging (R134a), AC compressor, evaporator, condenser, heater core, blower motor, control panel.
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections
Repair Overhaul:
Engine component replacement, transmission overhaul, brake caliper rebuild, suspension component replacement, steering rack repair
Diagnostics Troubleshooting:
Systematic diagnostic procedures, symptom-based troubleshooting guides, fault code interpretation
Disassembly Assembly:
Step-by-step instructions for removing, installing, and reassembling vehicle components
Specifications Data:
Torque specifications, clearances, fluid capacities, electrical specifications
Alignment Specifications:
Front and rear wheel alignment angles (camber, caster, toe), steering wheel centering.
Body Repair:
Panel replacement, dent repair, corrosion prevention, sealant application.
Depth:
Comprehensive, covering from basic maintenance to complex mechanical and electrical repairs, including diagnostic procedures.
Diagnostic Tools:
Procedures may require or reference the use of a Ford-specific diagnostic scan tool (e.g., WDS - Worldwide Diagnostic System) for advanced troubleshooting.
Engine Variants Covered:
1.6L Zetec-SE (1995-2000), 1.8L Zetec, 2.0L Zetec, 2.5L Duratec V6 (Mk II), 1.8L TD (Diesel), 2.0L TD (Diesel)
Power And Torque Ranges:
Varies by engine; e.g., 1.8L Zetec ~105-125 hp, 2.0L Zetec ~115-130 hp, 2.5L V6 ~170 hp. Specific figures available within the manual.
Fuel Delivery:
Multi-point fuel injection (MPI) for most petrol engines, direct injection for some later diesel variants. Includes fuel pump, injectors, fuel pressure regulator.
Ignition Type:
Electronic Ignition (EDIS - Electronic Distributorless Ignition System) on Zetec engines.
Cooling Type:
Pressurized liquid cooling system with thermostat-controlled fan.
Specific Engines:
1.6L (L1F, L1N, L1P), 1.8L (RKA, RKF, RKH, RKB), 2.0L (NGA, NGB, NGC, NGD), 2.5L V6 (LCBD, LCBB). 1.8TD (RTE, RTF), 2.0TD (RFN, RFU).
ECU Types:
Siemens, Lucas, Bosch ECUs depending on engine and model year. Includes diagnostic connectors and strategies.
Standard Transmission Type:
5-speed Manual Transmission
Optional Transmission Type:
4-speed Automatic Transmission (e.g., AX4N for V6 models)
Transmission Features:
Front-wheel drive (FWD), manual clutch operation, torque converter (automatic).
Manual Transmission Fluid:
API GL-4 or GL-5 specification, SAE 75W-90 (check specific manual for exact Ford specification e.g., WSD-M2C200-C)
Automatic Transmission Fluid:
Mercon V (or compatible fluid like Mercon SP, depending on specific transmission) (check specific manual for exact Ford specification e.g., WSS-M2C195-A)
Audio System:
Factory fitted radios with cassette players and CD changers (optional). Standard speaker configurations, with upgrade options.
Climate Control:
Manual air conditioning and heating, with optional automatic climate control on higher trim levels.
Cruise Control:
Optional cruise control system available on many models, integrated with engine management and throttle.
Parking Assistance:
Rear parking sensors were not common during this era; typically relied on driver awareness.
Oil Change Interval:
Typically every 10,000 miles or 12 months, whichever comes first. Diesel models might have slightly different intervals. Check manual for precise recommendations based on driving conditions.
Timing Belt Replacement:
For Zetec engines (e.g., 1.6L, 1.8L, 2.0L), timing belt replacement is crucial, typically every 60,000-100,000 miles or 5-6 years. Failure can cause catastrophic engine damage. V6 Duratec uses a timing chain.
Engine Oil Specification:
API SJ/SL or ACEA A3/B3, SAE 5W-30 or 5W-40 (check manual for specific viscosity based on ambient temperature and engine type). E.g., WSS-M2C153-E.
Coolant Specification:
Ford Super Plus Premium Antifreeze/Coolant (or equivalent) - a hybrid organic acid technology (HOAT) coolant. Typically a 50/50 mix with distilled water. Ford specification like WSS-M97B44-D.
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid (check manual for exact requirement). Ford specification like WSS-M6C65-A1.
Power Steering Fluid:
Automatic Transmission Fluid (ATF) - e.g., Mercon V or equivalent (check manual for exact Ford specification). Never use power steering fluid unless explicitly stated.
Common Problems:
Head gasket issues (especially on early 1.8L Zetec), rear wheel bearing premature wear, exhaust manifold cracks, door lock actuator failures, minor electrical gremlins, rust on older models.
Common Problems Cont:
Power steering pump leaks, MAF sensor issues, lambda sensor failure, radiator fan motor failure.
Ford History:
Ford has a long history of producing reliable and popular family cars, with the Mondeo succeeding the Ford Sierra and aiming to capture the mid-size family car market in Europe.
Generation Development:
The Mondeo was introduced as a 'world car' with advanced aerodynamics and safety features for its time. It underwent a significant facelift (Mk II) in 1996, introducing updated styling and technology.
Trim Levels:
GL, Ghia, LX, Si, Zetec, Trend, Ambiente, Titanium (varies by market and year).
Manufacturing Locations:
Primarily produced at Ford's plant in Valencia, Spain, and also in Belgium and the United States (as Ford Contour/Mercury Mystique).
