Ford - Mondeo III - Workshop Manual - 2002 - 2007

Kit Number 57-0599 Ford Mondeo III 3.0L 24v V6 2002-2007 Ford Mondeo III 2.5L 24v V6 2001-2005 Instruction sheet A2054-650 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. Disconnect the negative terminal from the battery. Unclip & remove the electrical harness plug from the MAS (Mass Air Sensor). (Fig. 1) Unclip & remove the intake hose from the MAS. (Fig. 2) ST220 ONLY Remove the air box feed pipe from the bottom of the air box base. (Fig.3) Carefully lift the complete air box assembly out of its mounting rubbers & remove the assembly from the vehicle. (Fig. 4) Assemble the saddle bracket / mounting bracket using the hardware supplied. (Fig. 5) Remove the left-hand front nut from the gearbox mounting assembly as shown. (Fig. 6) Fit the new mounting bracket assembly to the threaded stud on the gearbox mounting assembly & secure using the original nut. (Fig. 7) Unscrew & carefully remove the MAS from the air box lid as shown. (Fig. 8&9) Install the MAS into the K&N adaptor tube & secure using the small M4 bolts supplied. Note: Before installing the MAS, inspect the inside of the tube for any debris & clean if necessary. (Fig.10) Fit the MAS / adaptor tube assembly to the original intake hose & secure using the hose clamp supplied. (Fig.11&12) Note: The MAS adaptor supplied will be a loose fit in the intake hose but will tighten up securely Fit the rubber filter adaptor onto the end of the MAS adaptor tube as shown. (Fig.13&14) Fit the air filter onto the rubber filter adaptor & tighten the clip supplied. Note: Ensure the clip is placed around both the saddle bracket & air filter neck. (Fig.15&16) Reconnect the electrical harness plug to the MAS. (Fig.17) Unclip & remove the front grille from the vehicle. (Fig.18) Remove the end cap from the end of the air box feed pipe located next to the headlamp as shown. (Fig.19) Remove one of the end caps from the supplied flexi cold air hose. Fit the hose over the original air box feed pipe & secure using a plastic tie supplied as shown. (Fig.20) Refit the grille to the vehicle & secure the end of the flexi cold air hose to the grille using a plastic tie supplied. (Fig.21) Note: As a precaution drill a small water drain hole in the lowest point of the original pipe, this will be easier to carry out after completing inst. #19. Taking all the necessary safety precautions as per manufacturers instructions raise the front of the vehicle. Carefully remove the left hand road wheel & plastic wheel arch liner. ST220 ONLY Cut the plastic tie securing the original flexi air box feed hose to the chassis leg located behind the previously removed wheel arch liner as shown. (Fig.22) ST220 ONLY From under the vehicle cut the second clip securing the original flexi air box feed hose to the lower cross member as shown. (Fig.23) ST220 ONLY Pull the original flexi air box feed hose from the wheel arch area & re-route the hose to the lower under tray. Drill 2 holes in the under tray & secure the hose facing forward using a plastic tie supplied. (Fig.24) ST220 ONLY Refit the wheel arch liner & road wheel to the vehicle. Note: Ensure that the manufacturer’s instructions & recommended safety precautions are followed. Reconnect the negative battery terminal. Carry out a final check of the height / alignment of the K&N induction system before starting the engine. Installation is now complete. Fig. # 1 Fig. # 5 www.knfilters.com Fig. # 2 Fig. # 6 Fig. # 3 Fig. # 7 Parts list: 1 x Air filter Element 1 x Aluminum Adaptor Tube 1 x Rubber Filter Adaptor 1 x Flexi Cold Air Hose 1 x Literature Pack Fixing Kit :1 x 70/90 Hose Clamp 1 x 100/120 Hose Clamp 4 x Plastic Tie 1 x ‘L’ Bracket 1 x Saddle Bracket 1 x M6 Flat Washer 1 x M6 Nylock Nut 1 x M6 C’sunk Bolt 1 x Nylon Conical Washer 2 x M4 Allen Head Bolt WARNING: Before starting the engine carry out a final fitment check of the K&N performance kit. It will be necessary for all intake systems to be checked periodically for realignment, clearance and tightening of all connections. Failure to follow the above instructions or proper maintenance may void the warranty. FILTER MAINTENANCE: K&N suggests checking the filter periodically for excessive dirt build-up. When the element becomes covered in dirt (or once a year), service it according to the instructions on the Recharger service kit available from your K&N dealer, part number 995000 or 99-5050. Fig. # 4 Fig. # 8 Technical Support: [email protected] UK technical enquiries: phone the R&D department at 01925-636950, Mon-Thu from 7.00 am to 5 pm 57-0599 A2054-650 Fig. # 9 Fig. # 10 Fig. # 11 Fig. # 12 Fig. # 13 Fig. # 14 Fig. # 15 Fig. # 16 Fig. # 17 Fig. # 18 Fig. # 19 Fig. # 20 Fig. # www.knfilters.com Fig. # 22 Fig. # 23 Fig. # 24 Technical Support: [email protected] UK technical enquiries: phone the R&D department at 01925-636950, Mon-Thu from 7.00 am to 5 pm