All about Ford Mondeo

General information and precautions
Fuel and exhaust systems / General information and precautions


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 crossreferences 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. DonТt smoke, or allow open flames or bare light bulbs, near the work area.

DonТt 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 УSafety first!Ф 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.


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