General information on engine repair (Mondeo 1)

Contents: Petrol engines ↳ Diesel engines ↳

The Ford Mondeo has a liquid-cooled, four-cylinder, in-line engine mounted at the front, transverse to the direction of travel. The engine can only be removed with a crane and only downwards.

The cylinder block, made of gray cast iron, contains the cylinders. In the case of severe wear of the cylinders or the formation of grooves on the walls, they can be honed in a specialized workshop. After honing, the pistons must be installed in the cylinders with tension. The crankshaft is located at the bottom of the cylinder block. Bearings serve as support points for it. The connecting rods connected to the pistons communicate with the crankshaft through rolling bearings. At the very bottom of the cylinder block is an oil pan, which contains oil needed to lubricate and cool the engine. The cylinder head is located on top of the cylinder block

Depending on the model, either a DOHC petrol engine or an OHC diesel engine is used.

Petrol engines

DOHC engines (Double Overhead Camshaft = two overhead camshafts) use two camshafts located in the cylinder head. One camshaft controls the exhaust valves, the other the intake valves. Both camshafts are driven by the crankshaft via a toothed belt. The camshafts operate the valves by acting on them through hydraulic tappets (valve clearance compensators), with which there is no need to adjust the valve clearances.

The cylinder head is made of light metals (aluminum), and the principle of horizontal flows was used in its creation. This means that fresh fuel-air mixture enters from one side of the cylinder head, while exhaust gases are ejected from the opposite side. Horizontal flows provide rapid gas exchange.

The cylinder block houses a coolant pump, which, like the camshafts, is driven by a toothed belt. The gear oil pump is driven directly by the crankshaft via a camshaft journal. A multi-point injection system is used to prepare the ignitable fuel-air mixture. Ignition is performed by a distributorless ignition system, i.e. the traditional ignition distributor is replaced by electronic components. Auxiliary units such as the generator, servo pump, and air conditioning compressor are driven by a maintenance-free V-belt.

Diesel engines

The term OHC (Overhead Camshaft) indicates that the camshaft is located on top of the cylinder head. The cylinder head and cylinder block are made of gray cast iron. The crankshaft drives the camshaft and the coolant pump via a toothed belt. The perpendicularly arranged valves are driven by the camshaft directly via plate tappets. The valve clearances must be checked regularly as part of each maintenance; adjusting washers of the appropriate thickness are used to adjust the clearances.

The second toothed belt drives the injector distributor pump, which generates the pressure required to inject diesel fuel.

Auxiliary units such as the generator, servo pump and air conditioning compressor are driven by a separate V-belt.

Warning! The electric cooling fan may turn on by itself when the engine is off and the ignition is on. This can happen many times due to the heat accumulated in the engine compartment. Therefore, when the engine is hot, you should always consider the possibility of the fan turning on unexpectedly. Therefore, when working in the engine compartment, if possible, you should always turn off the ignition.

The engine number is stamped on the cylinder block; in petrol engines the number is located at the height of the starter, in addition it is on the cylinder head near the gearbox in diesel engines the number is on the left above the high-pressure fuel pump.

Engine code "1" is indicated on the nameplate located at the front of the engine compartment. The year and month of model production are encoded in the chassis number "2".

Rank 1: asterisk (*)

Levels 2, 3 and 4: International branches of the manufacturer

SFA - Ford Motor Company Ltd. United Kingdom
WFO - Ford Werke AG, Germany (European models)
WFO - Ford Werke AG, Germany (USA models)
UN1 - Henry Ford & Son Ltd - Ireland
XLC - NVNederland Ford - Netherlands
VS6 - Ford Espana SA - Spain
TW2 - Ford Lusitana SARL - Portugal
9BF - Ford - Brazil

Numbers 5-11: model variants

BF - Four-door limousine
VA - Five-door limousine
BN - Combi (Tournament) four-door

Digits 6 and 7: XX (filling places)

Category 8: Manufacturer

B - Ford England - own production
G - Ford Germany - own production
C - Ford England - assembly by other branches of the concern
E - Ford Germany - assembly by other branches of the concern W - Ford Spain - own production
L - Ford Brazil - own production

Category 9: Assembly Plant