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Sven Nielsen, Technical Director from MEYLE, talks CAT through issues with the Ford Mondeo:

1. Damaged glow plugs

Problem: Cold starting problems due to damaged glow plugs.

MEYLE Solution: MEYLE offers high-quality glow plugs designed to provide great durability even at sub-zero temperatures. Using a latest-generation Kanthal wire ensures rapid temperature generation in the combustion chamber and offers exceptionally long service life. In addition, MEYLE glow plugs start glowing at the tip, then voltage is reduced. This allows the engine to start faster while going easy on the battery and the environment.

Although not yet a common sight in the independent workshop, technicians nonetheless need to be aware that the 116PS 1.6 TDCi and 160PS 1.6 EcoBoost engines fitted in the ECOnetic models introduced in June 2011, feature Ford’s Auto-Start-Stop technology. This means that the batteries used for these variants are not traditional lead-acid starter batteries and those undertaking battery replacement will therefore require specialist knowledge and equipment to ensure the correct removal and installation process is followed.

This model fitted with the 1.8L and 2.0L TDCi engines can suffer with the Variable Geometry turbo sticking which results in a loss of power and performance and the engine management light coming on storing a fault code for turbo boost condition. The fault is caused by incomplete combustion and soot particles in the exhaust gases sticking to the turbo vanes, which are baked on due to heat. This can also happen after the vehicle has been sitting at speed on the motorway for a long period. When stopping at services, for example, the next start-up can cause an over-boost situation where the vanes of the turbo are stuck open. In some cases this can blow the intake pipe off the air box.

Mondeo IV Rear Trailing Arm Bushes

Alongside its reputation for quality replacement parts, First Line is also renowned for its ability to find the solutions and introduce the products that technicians really need to resolve their repair problems. One such example is the rear trailing arm bush for the Mk IV Ford Mondeo.

Historically the suspension system on this vehicle has presented a challenge to the independent sector because the failure of the rear trailing arm bushes has meant that the complete trailing arm has had to be replaced.

Corteco advises garage mechanics to examine the Torsional Vibration Damper pulley on these models for wear. Worn TVDs can adversely affect the performance of other components in the auxiliary belt drive system, which may be replaced in error.

Consequences are customer dissatisfaction when the problems recur and potential drive system failure if the wear continues to go undetected.

As one of the largest suppliers of TVDs, Corteco suggests that TVD replacement - as part of the scheduled drive belt replacement programme - is the sensible and preferred option. Note that TVDs are model specific, TVD bolts are not designed for re-use and must be replaced with the correct bolt for the application. Torque settings are critical.

1. Engine Oil

• For this particularly series of Mondeo, Ford list only one or two specifications for engine oil which should be covered by Comma Xtech 5W30. However, always use Comma’s application guide to make sure you get the right product for the vehicle you are servicing.

Steering

Customers may complain of excessive noise coming from the power steering pump. Typically this is a result of the power steering power rack seals failing, which causes the steering fluid to become contaminated. This in turn causes the power steering pump to become blocked, leading to the power steering pump becoming overly noisy.

Technicians should firstly check the pump filter for debris and blockages. They should also check to see if the fluid is foaming, due to a blockage. A replacement steering rack will need to be fitted. At a minimum the filter will need to be cleaned or replaced. Finally, it’s vital that technicians ensure that the whole system has been flushed and cleaned before fitting new components to avoid re-contamination.

The 2007 Ford Mondeo was launched with a new range of engines, following a trend for downsizing over the previous model.  For petrol engines, the 1.8-litre was replaced by a new 1.6-litre unit, while the thirsty 3.0-litre engine was dropped from the range altogether.  The popular 2.0-litre petrol engine was retained.  For its diesel models, Ford introduced new 1.6-litre and 1.8-litre engines alongside the established 2.0-litre and 2.2-litre units.

Castrol points out that every engine in the current generation Ford Mondeo was designed to run on fully-synthetic, low viscosity Castrol Magnatec 5W-30 A1 engine oil.

These are the parts that Cambiare believe needs extra attention:

The ignition leads are a weak spot, with 44 percent of Cambiare’s top ten sales for this car are these parts, followed by ignition coils at 30 percent.

TDCi suffer turbo problems causing black smoke from the exhaust resulting in power loss. A seized or blocked EGR valve can give the same symptoms.

No common issues apart from 1.8 and 2.0 TDCi diesel models can have sticking Starter Motor issues caused by Clutch and DMF dust contamination, this can result in intermittent starter failure or burn out if stuck in the engaged position.

Before fitting this replacement alternator please check the alternator that has been removed from the vehicle. If the pulley is seized, spinning freely in both directions without the alternator turning, has collapsed or is missing; the TVD (Torsional Vibration Damper or ‘bottom/crankshaft pulley’) needs to be inspected, otherwise the replacement alternator pulley will also fail prematurely.

As it can be seen the TVD has started to crack and break away from its mounting point