leaking into a car can be particularly annoying. With all brand
new car designs there will be problems that get corrected as time
goes on and improvements made, however there are a couple of common
areas in which water can leak into the mondeo.
Area 1: Front Passenger Side Foot Well
is nearly always caused by a leaking pollen filter. Air enters the
cabin via a filter hidden under the windscreen grill on the passenger
side. With time this filter disintegrates and the seal strip around
it fails allowing water to enter the ventilation system and drip
onto the passenger side carpet and there are two methods used to
help cure this.
first is for pre 95 cars which have the windscreen grill in the
true sense that it is a grill - later models had a look-a-like grill
that covered the pollen filter preventing water from dripping directly
on to it. This also gives the added benefit of restricting the amount
of "wet" air entering the cabin, thus reducing the amount
of steam that builds up on the windscreen. Replacing the cover is
a 10 minute job and Mk1 and Mk2 covers are interchangeable, so finding
one shouldn't be a problem. To replace the grill follow the instructions
below for replacing the filter:
second is replacing the filter. This should be done at 20,000 mile
intervals or if you use the car a lot in dusty conditions. Of course
variations will occur so use your own judgment as to when the air
supply into the car feels restricted.
the covering grill is a little tricky the first time you do it,
you'll need a size 27 thorx screwdriver and also a philips (+ style)
screwdriver together with a small flat object for removing the blanking
plates. Its held down by three thorx bolts and two plastic expanding
plugs, opened via a screw.
the bonnet open peel back the rubber sealing strip attached to the
edge of the grill (A). Next undo and remove the three thorx bolts
(B). Some models will have a plastic/rubber water deflector (D)
which needs to be pulled off. Finally prise off the two screw cap
covers (C) and loosen the screws underneath - these don't need to
be removed, just slackened as all they do is open the plastic expanding
all the retaining clips and bolts removed the grill will lift off
- however this is the slightly tricky part as its held in place
by lips that go under the drivers side of the grill and the passenger
side wing. Its easiest to try and slide the grill to the right and
free the lip under the other have of the grill first before extracting
it from the wing side.
it removed you'll be able to see the pollen filters plastic cover
which is held in place by two metal spring clips, unclip these and
lift out the cover - complete with old filter. The new filter should
only fit one way and an arrow showing air flow is normally drawn
on to it. HCF201 is the halfords code for the mondeo filter and
costs about £8.50 (FINIS: 93BW-16N619-AB)
you have installed the new filter in the cover, replace it and ensure
the metal spring clips are securing it correctly. It should be fairly
tight and not wobble around much - if it isn't then check its sat
on the base correctly and that nothing is damaged else water might
still be able to penetrate it.
the grill cover (again its easiest to fit the wing side lip under
first). Do up the thorx bolts first and then tighten the screws
remembering that they only open plastic plugs and so don't get tight!
Over tightening them will result in the plug snapping away from
the grill. Remember to replace the rubber seal and if removed the
deflecting strip (D)
this doesn't fix the problem you'll find whats happening is water
is getting in between the filter housing and the bulkhead and then
dripping down, again this is easily fixable but you'll need a size
13mm socket and some silicon seal. Turn off air distribution before
doing this (set the direction switch to the O position) Follow the
instructions above to remove the filter and assembly from the car,
then undo the two 13mm bolts either side of the housing bolted to
these two removed you can withdraw the assembly and grill from the
car entirely leaving with you access to the air intake as shown
you can see with this picture the water has been penetrating the
seal and allowing water and rubbish to build up, note the mank on
the grill (bottom right) which could have been sucked into the motor.
The lip running around the intake hole is supposed to stop water
from entering the cabin but unfortunately with a poor seal it runs
around the lip and then down the gap between the bulkhead and the
internal grill (arrowed). To fix this we need to first thoroughly
clean the mating surfaces on both the bulkhead and the back of the
plastic you just removed. Once they are clean apply a thick layer
of silicone seal around the bulkheads lip and around the back of
the plastic, then refit the assembly and bolt it back into position.
it replaced use a little more to seal the gaps between the plastic
and the lip from the inside as shown in the inset picture. If possible
allow a couple of hours for the seal to set before replacing the
filter and cover. Obviously because of where we are applying the
seal, the car will smell of silicone every time you put the fan
on for about a week afterwards but this will stop and keep the car
Area 2: Drivers Foot Well
really effecting early Mk1 mondeo's with cable driven speedos. There
is a rubber seal on the cable as it enters the bulkhead (under the
drivers side windscreen grill - removal the same as for passenger
grill shown above). If its perished then water can enter and drip
down on to the drivers side foot well including landing on the brake
pedal! After removing the drivers side grill, examine the cable
entry point for gaps. The cable won't move much so cover the entire
entry point in silicon sealant or equivalent.
Area 3: Bottom of Doors
a number of Mk3 cars (although it can effect Mk1 and Mk2 equally)
this is caused by a poorly seated weather seal inside the car. Remove
the door card and look at the foam panel stuck to the door,
you can see in this photo the bottom right corner of this panel
is beginning to rot and allow water through, the other common fault
here is that the panel isn't properly stuck to the door. During
the summer periods the glue heats up and can allow the panel to
become unstuck and as a result water leaks into the car between
the doorcard and door.
Area 4: Boot
caused by a worn seal between rear light cluster and the body on
Mk2's although a damaged weather seal around the boot would also
cause problems. The clusters are removed from inside the car - disconnect
the wiring connector and withdraw the bulb holding unit. You should
see a number of bolts that hold the cluster to the body - remove
all of these and pull the cluster from the outside to withdraw it.
New gaskets are available from ford however using a clear setting
silicone sealant works just as, if not better, then the gaskets.
can also suffer from leaking clusters although the problem is more
likely to be a loose tailgate caused by wear/tear and vibration
over the years - especially if your boot is very easy to close.
Correctable by adjusting the locking mechanism's mounting bolts.
With the boot open remove the screws on the rear plastic scuff panel.
Then prise out the two larger plastic retaining lugs. Tug the panel
to dislodge it and gain access to the mechanism.
two retaining lugs are shown here as point "A" (Large
Thorx Bolts) Slacken them both and work the mechanism a little lower.
Tighten and attempt to shut the boot - it should shut easily with
a little pressure, you shouldn't have to put a lot of effort into
shutting it however you may find that a couple of attempts are required
to get the position perfect. With the slack boot water is entering
at the bottom of the boot seal but with an overtight boot it is
likely to enter at the top of the seal so its important to get the
tension right. Take your time and make small adjustments over time.
when we looked at our own car it was worth noting that over the
years the plastic scuff panel has scraped off the paint from under.
The result was little patches off rust beginning to form, they were
therefore treated with rustcure and later the area was painted and
lined with a soft foam to stop reoccurrence. Therefore don't be
to surprised if you discover rust when you do your own but it shouldn't
be left untreated as over time it will spread.
Area 5: Sunroof
have always been a cause for concern in wet weather however the
mondeo sunroof is well designed - even with a damaged outer seal
water shouldn't really be able to reach the cabin due to drain pan
and pipes in all four corners of the sunroof. However if these get
blocked then water won't be able to escape and so could leak into
the car. If this is happening, or you have water in any of the four
corners of the cabin then this should be checked. Behind the A pillar
trims and the C pillar trims are the large black with white striped
drain pipes. There are joints in there so undo and inspect for blockages.