All about Ford Mondeo

Air cleaner assembly and air intake components - removal and refitting
Fuel and exhaust systems / Air cleaner assembly and air intake components - removal and refitting


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).

4.3 Disconnecting the crankcase breather hose from the cylinder head union
4.3 Disconnecting the crankcase breather hose from the cylinder head union

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.

4.4 Remove rubber retaining band to withdraw air cleaner assembly
4.4 Remove rubber retaining band to withdraw air cleaner assembly

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).

4.5 Ensure air filter housing intake mouth is fully engaged inside connector
4.5 Ensure air filter housing intake mouth is fully engaged inside connector sleeve

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 sensors electrical connector (see illustration). Withdraw the resonator.

4.7 Unplugging intake air temperature sensors electrical connector
4.7 Unplugging intake air temperature sensors electrical connector

8 Refitting is the reverse of the removal procedure.

Plenum chamber
9 Prising out the rubber plugs covering them, undo the chambers fasteners (see illustration). Slacken the clamp screw securing the chamber to the resonator hose.

4.9 Plenum chamber fasteners (arrowed) - four shown here, some vehicles may
4.9 Plenum chamber fasteners (arrowed) - four shown here, some vehicles may only have three

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 housing stud) and the sealing O-ring in the chambers mouth (see illustrations).

4.10A Lift plenum chamber and (where fitted) disconnect the vacuum hose -
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 chambers mouth
4.10B . . . and the sealing O-ring (arrowed) in the chambers mouth

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.


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