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Ford Mondeo (petrol engines). Manual - part 25

Chapter 4 Fuel and exhaust systems

Accelerator cable (models with traction control) -

removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . . . . . . .

Accelerator cable (models without traction control) -

removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . . . . . . .

Accelerator pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . .

Air cleaner assembly/air intake components - removal and refitting .

Air filter element renewal . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 1

Catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 6

Exhaust manifold - removal and refitting . . . . . . . . . . . See Chapter 2A
Exhaust system - general information and component renewal . . . . 17
Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 1

Fuel cut-off switch - removal and refitting . . . . . . . . . . . . . . . . . . . . 13
Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 1

Fuel injection system/engine management system - check . . . . . . . 15
Fuel injection system/engine management system - general . . . . . 14

Fuel lines and fittings - general information . . . . . . . . . . . . . . . . . . .

Fuel pump/fuel gauge sender unit - removal and refitting . . . . . . . .

Fuel pump/fuel pressure - check . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel system - depressurisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel system components - check and renewal  . . . . . . . . . . . . . . . . 16
Fuel tank - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuel tank cleaning and repair - general information  . . . . . . . . . . . . . 11
General information and precautions  . . . . . . . . . . . . . . . . . . . . . . . .

Idle speed and mixture check and adjustment  . . . . . . See Section 14
Inlet manifold - removal and refitting  . . . . . . . . . . . . . . See Chapter 2A
Oxygen sensor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 6

Roll-over valves - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 12
Underbody fuel/brake line check . . . . . . . . . . . . . . . . .

See Chapter 1

Underbonnet hose check . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 1

General

Idle speed:

Regulated - nominal (± 50 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

830 to 880 rpm*

Unregulated - base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1500 rpm*

Idle mixture (CO level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not available

* Given for reference only - not adjustable.

Rev limiter operation

Fuel injectors shut off at:

Automatic transmission, position “N” selected . . . . . . . . . . . . . . . . . .

4100 rpm

Automatic transmission, any other position selected . . . . . . . . . . . . .

6800 rpm (approximately)

Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6800 to 7100 rpm

Fuel pressure

Regulated fuel pressure - engine running at idle speed:

Pressure regulator vacuum hose connected . . . . . . . . . . . . . . . . . . .

2.1 ± 0.2 bars

Pressure regulator vacuum hose disconnected . . . . . . . . . . . . . . . . .

2.7 ± 0.2 bars

Note: When the ignition is switched off, the system should hold 1.8 bars for 5 minutes. If the engine is hot, the pressure may rise to maximum of
2.7 bars during this check. Pressure regulator (when reconnected) should prevent any higher pressure being reached.

Fuel injectors

Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13.7 to 15.2 ohms

Idle speed control valve

Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 to 14 ohms

Idle-increase solenoid valve

Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 to 120 ohms

Torque wrench settings

lbf ft

Plenum chamber-to-inlet manifold fasteners . . . . . . . . . . . . . . . . . . . . .

Throttle housing-to-inlet manifold screws . . . . . . . . . . . . . . . . . . . . . . .

Idle speed control valve bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel pressure regulator bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel injector bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel rail-to-inlet manifold bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel feed and return line threaded couplings at fuel rail . . . . . . . . . . . . .

24 to 30

17 to 22

All exhaust system nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 to 45

30 to 33

4•1

Easy, suitable for
novice with little
experience

Fairly easy, suitable
for beginner with
some experience

Fairly difficult, suitable
for competent DIY
mechanic

Difficult, suitable for
experienced DIY
mechanic

Very difficult,
suitable for expert DIY
or professional

Degrees of difficulty

Specifications

Contents

This Chapter is concerned with those

features of the engine management system
that supply clean fuel and air to the engine,
meter it in the required proportions, and
dispose of the results. Since the emission
control sub-systems modify the functions of
both the fuel and exhaust sub-systems, all of
which are integral parts of the whole engine
management system, there are many cross-
references to Chapters 5 and 6. Information
on the electronic control system, its fault
diagnosis, sensors and actuators, is given in
Chapter 6.

The air intake system consists of several

plastics components designed to eliminate
induction roar as much as possible. The air
intake tube (opening behind the direction
indicator/headlight assembly) is connected,
via small and large resonators located under
the front left-hand wing, to the air cleaner
assembly in the engine compartment. Once it
has passed through the filter element and the
air mass meter, the air enters the plenum
chamber mounted above the throttle housing
and inlet manifold; the resonator mounted in
the engine compartment further reduces noise
levels.

The fuel system consists of a plastic tank

(mounted under the body, beneath the rear
seats), combined metal and plastic fuel hoses,
an electric fuel pump mounted in the fuel tank,
and an electronic fuel injection system.

The exhaust system consists of an exhaust

manifold, the front downpipe and catalytic
converter and, on production-fit systems, a
rear section incorporating two or three
silencers and the tailpipe assembly. The
service replacement exhaust system consists
of three or four sections: the front
downpipe/catalytic converter, the
intermediate pipe and front silencer, and the
tailpipe and rear silencer. On some versions,
the tailpipe is in two pieces, with two rear
silencers. The system is suspended
throughout its entire length by rubber
mountings.

Extreme caution should be exercised when

dealing with either the fuel or exhaust
systems. Fuel is a primary element for
combustion. Be very careful! The exhaust
system is an area for exercising caution, as it
operates at very high temperatures. Serious
burns can result from even momentary
contact with any part of the exhaust system,
and the fire risk is ever-present. The catalytic
converter in particular runs at very high
temperatures - refer to the information in
Chapter 6.

Warning: Many of the procedures
in this Chapter require the
removal of fuel lines and
connections, which may result in

some fuel spillage. Petrol is extremely
flammable, so take extra precautions

when you work on any part of the fuel
system. Don’t smoke, or allow open flames
or bare light bulbs, near the work area.
Don’t work in a garage where a natural
gas-type appliance (such as a water
heater or clothes dryer) with a pilot light is
present. If you spill any fuel on your skin,
rinse it off immediately with soap and
water. When you perform any kind of work
on the fuel system, wear safety glasses,
and have a Class B type fire extinguisher
on hand. Before carrying out any operation
on the fuel system, refer also to the
precautions given in “Safety first!” at the
beginning of this manual, and follow them
implicitly. Petrol is a highly-dangerous and
volatile liquid, and the precautions
necessary when handling it cannot be
overstressed.

Warning: The fuel system will
remain pressurised for long
periods of time after the engine is
switched off - this pressure must

be released before any part of the system
is disturbed. Petrol is extremely
flammable, so take extra precautions
when you work on any part of the fuel
system. Don’t smoke, or allow open flames
or bare light bulbs, near the work area.
Don’t work in a garage where a natural
gas-type appliance (such as a water
heater or clothes dryer) with a pilot light is
present. If you spill any fuel on your skin,
rinse it off immediately with soap and
water. When you perform any kind of work
on the fuel system, wear safety glasses,
and have a Class B type fire extinguisher
on hand.
1 The fuel system referred to in this Chapter
is defined as the fuel tank and tank-mounted
fuel pump/fuel gauge sender unit, the fuel
filter, the fuel injectors and the pressure
regulator in the injector rail, and the metal
pipes and flexible hoses of the fuel lines
between these components. All these contain
fuel, which will be under pressure while the
engine is running and/or while the ignition is
switched on.
2 The pressure will remain for some time after
the ignition has been switched off, and must
be relieved before any of these components is
disturbed for servicing work.
3 The simplest method is simply to
disconnect the fuel pump’s electrical supply
while the engine is running - either by
removing the fuel pump fuse (number 14), or
by lifting the red button on the fuel cut-off
switch (see Section 13) - and to allow the
engine to idle until it dies through lack of fuel
pressure. Turn the engine over once or twice
on the starter to ensure that all pressure is
released, then switch off the ignition; do not
forget to refit the fuse (or depress the red

button, as appropriate) when work is
complete.
4 The Ford method of depressurisation is to
use service tool 29-033 fitted to the fuel rail
pressure test/release fitting - a Schrader-type
valve with a blue plastic cap, located on the
union of the fuel feed line and the fuel rail - to
release the pressure, using a suitable
container and wads of rag to catch the spilt
fuel. Do not simply depress the valve core to
release fuel pressure - droplets of fuel will
spray out, with a consequent risk of fire, and
of personal injury through fuel getting into
your eyes.

Warning: Either procedure will
merely relieve the increased
pressure necessary for the
engine to run. Remember that

fuel will still be present in the system
components, and take precautions
accordingly before disconnecting any of
them.
5 Note that, once the fuel system has been
depressurised and drained (even partially), it
will take significantly longer to restart the
engine - perhaps several seconds of cranking
- before the system is refilled and pressure
restored.

Warning: The fuel system
pressure must be released before
any part of the system is
disturbed - see Section 2. Petrol

is extremely flammable, so take extra
precautions when you work on any part of
the fuel system. Don’t smoke, or allow
open flames or bare light bulbs, near the
work area. Don’t work in a garage where a
natural gas-type appliance (such as a
water heater or clothes dryer) with a pilot
light is present. If you spill any fuel on your
skin, rinse it off immediately with soap and
water. When you perform any kind of work
on the fuel system, wear safety glasses,
and have a Class B type fire extinguisher
on hand.

Disconnecting and connecting
quick-release couplings

1 Quick-release couplings are employed at all
unions in the fuel feed and return lines.
2 Before disconnecting any fuel system
component, relieve the residual pressure in
the system (see Section 2), and equalise tank
pressure by removing the fuel filler cap.

Warning: This procedure will
merely relieve the increased
pressure necessary for the
engine to run - remember that

fuel will still be present in the system
components, and take precautions
accordingly before disconnecting any of
them.

3 Fuel lines and fittings -

general information

2 Fuel system - depressurisation

1 General information and

precautions

4•2 Fuel and exhaust systems

3 Release the protruding locking lugs on each
union, by squeezing them together and
carefully pulling the coupling apart. Use rag to
soak up any spilt fuel. Where the unions are
colour-coded, the pipes cannot be confused.
Where both unions are the same colour, note
carefully which pipe is connected to which,
and ensure that they are correctly
reconnected on refitting (see illustration).
4 To reconnect one of these couplings, press
them together until the locking lugs snap into
their groove. Switch the ignition on and off
five times to pressurise the system, and check
for any sign of fuel leakage around the
disturbed coupling before attempting to start
the engine.

Checking

5 Checking procedures for the fuel lines are
included in Chapter 1.

Component renewal

6 If you must renew any damaged sections,
use original-equipment replacement hoses or
pipes, constructed from exactly the same
material as the section you are replacing. Do
not install substitutes constructed from
inferior or inappropriate material, or you could
cause a fuel leak or a fire.
7 Before detaching or disconnecting any part
of the fuel system, note the routing of all
hoses and pipes, and the orientation of all
clamps and clips. Replacement sections must
be installed in exactly the same manner.

8 Before disconnecting any part of the fuel
system, be sure to relieve the fuel system
pressure (see Section 2), and equalise tank
pressure by removing the fuel filler cap. Also
disconnect the battery negative (earth) lead -
see Chapter 5, Section 1. Cover the fitting
being disconnected with a rag, to absorb any
fuel that may spray out.

Air cleaner assembly

1 Disconnect the battery negative (earth) lead
- see Chapter 5, Section 1.
2 Unclip the air mass meter from the air
cleaner cover (see Chapter 6).
3 Disconnect the crankcase breather hose,
either from the air cleaner housing or from the
cylinder head cover union (see illustration).
4 Remove the rubber retaining band (see
illustration). Withdraw the air cleaner
assembly, lifting it upwards out of its
grommets, and releasing it from the rubber
connector sleeve in the inner wing panel.
5 Refitting is the reverse of the removal
procedure. Ensure that the housing pegs seat
correctly in their grommets, and that the
intake mouth is fully engaged inside the
connector sleeve (see illustration).

Air intake components

Note: Depending on the reason for removal,
these components can be removed either
individually, or as one assembly. For example,
unplugging the two electrical connectors and
disconnecting the vacuum hose (where fitted),
will allow the air cleaner assembly cover to be
removed with the air mass meter, the
resonator and the plenum chamber.

Air mass meter

6 Refer to Section 4 of Chapter 6.

Resonator (engine compartment)

7 Unbolt the resonator support bracket from
the engine compartment front crossmember.
Slacken the two clamp screws securing the
resonator to the air mass meter and plenum
chamber hoses. Swing the resonator clear of
the thermostat housing, and unplug the intake
air temperature sensor’s electrical connector
(see illustration). Withdraw the resonator.
8 Refitting is the reverse of the removal
procedure.

Plenum chamber

9 Prising out the rubber plugs covering them,
undo the chamber’s fasteners (see
illustration). Slacken the clamp screw
securing the chamber to the resonator hose.
10 Lift the chamber and (where fitted)
disconnect the vacuum hose from its
underside. Withdraw the chamber - note the
two rubber spacers (one on each throttle

4 Air cleaner assembly and air

intake components -
removal and refitting

Fuel and exhaust systems 4•3

4.5 Ensure air filter housing intake mouth

is fully engaged inside connector sleeve

4.7 Unplugging intake air temperature

sensor’s electrical connector

4.9 Plenum chamber fasteners (arrowed) -

four shown here, some vehicles may only

have three

3.3 Disconnect fuel line quick-release

couplings by squeezing together protruding

locking lugs and pulling coupling apart

4.3 Disconnecting the crankcase breather

hose from the cylinder head union

4.4 Remove rubber retaining band to

withdraw air cleaner assembly

housing stud) and the sealing O-ring in the
chamber’s mouth (see illustrations).
11 Refitting is the reverse of the removal
procedure. Ensure that the O-ring and
spacers are correctly seated.

Underwing components

12 Remove the left-hand wheel arch liner
(see Chapter 11).
13 Unbolt and withdraw the air intake tube
and both resonators as required.
14 Refitting is the reverse of the removal
procedure.

Removal

1 Disconnect the battery negative (earth) lead
- see Chapter 5, Section 1.
2 Remove the plenum chamber (see Sec-
tion 4).
3 Remove the clip securing the cable to the
throttle housing bracket (see illustration).
Disconnect the cable end nipple from the
throttle linkage, and release the cable from
any securing clips or ties.
4 Working in the passenger compartment,
reach up to the top of the accelerator pedal.
Pull the end fitting and collar out of the pedal,

then release the cable inner wire through the
slot in the pedal (see illustration). Tie a length
of string to the end of the cable.
5 Returning to the engine compartment, pull
the cable through the bulkhead until the string
can be untied and the cable removed.

Refitting

6 Refitting is the reverse of the removal
procedure; use the string to draw the cable
through the bulkhead.
7 Adjust the cable as described below.

Adjustment

8 Remove the plenum chamber (see Sec-
tion 4).
9 Find the cable adjuster - this is either at the
throttle housing bracket, or two-thirds along
the length of the cable, clipped to the front
suspension right-hand mounting (see
illustration). Remove the metal clip and
lubricate the adjuster’s grommet with soapy
water.
10 Remove any slack by pulling the cable
outer as far as possible out of the adjuster.
Have an assistant depress the accelerator
pedal fully - the cable outer will move back
into the adjuster - and hold it there while the
clip is refitted.
11 Check that the throttle valve moves
smoothly and easily from the fully-closed to
the fully-open position and back again, as the
assistant depresses and releases the

accelerator pedal. Re-adjust the cable if
required.
12 When the setting is correct, refit the
plenum chamber (see Section 4).

Removal

Note: While the following procedure deals
with the complete cable, the pedal-to-
actuator and actuator-to-throttle housing
sections of the cable are available separately,
and can be removed and refitted individually.
If doing this, modify the procedure as
required.
1 Disconnect the battery negative (earth) lead
- see Chapter 5, Section 1.
2 Remove the plenum chamber (see Sec-
tion 4).
3 Remove the clip securing the cable to the
throttle housing bracket, then pull the cable’s
grommet out of the bracket. Disconnect the
cable end nipple from the throttle linkage, and
release the cable from any securing clips or
ties.
4 Unplug the TCS throttle actuator’s electrical
connector, and prise off its cover (see
illustration).
5 Noting which cable section is connected to

6 Accelerator cable (models

with traction control) -
removal, refitting and adjustment

5 Accelerator cable (models

without traction control) -
removal, refitting and adjustment

4•4 Fuel and exhaust systems

4.10A Lift plenum chamber and (where

fitted) disconnect the vacuum hose - note

the two rubber spacers (arrowed) . . .

4.10B . . . and the sealing O-ring (arrowed)

in the chamber’s mouth

5.3 Removing clip securing accelerator

cable to throttle housing bracket

5.4 Pull the accelerator cable end fitting

(arrowed) out of the pedal

5.9 Location of accelerator cable adjuster

- remove metal clip (arrowed) to enable

adjustment to be made

6.4 Unplug TCS throttle actuator’s

electrical connector (A), and prise off its

cover at two points (B)

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