Description and operating principle (1.6L Zetec-SE/1.4L) Fuel supply and controls Pos. Spare Part No Name 1 Fuel pressure regulator 2 Fuel manifold 3 Injector mounting clamp 4 Nozzle O - rings 5 Fuel injector The fuel rail is...
Diagnostics and checks (1.6L Zetec-SE/1.4L) Inspection and verification 1. Check the validity of the customer's complaint by using the system. 2. Visually inspect for obvious signs of mechanical and electrical...
Throttle body (1.6L Zetec-SE/1.4L) Removal CAUTION: Do not attempt to clean the throttle body. The bore and throttle plate have a special coating applied during manufacture that must not be removed. 1....
Fuel injectors (1.6L Zetec-SE/1.4L) Removal WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working with or near fuel-related items. Highly flammable mixtures are always...
Fuel Supply Manifold (1.6L Zetec-SE/1.4L) Removal WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working with or near fuel-related items. Highly flammable mixtures are always...
Fuel pressure regulator (1.6L Zetec-SE/1.4L) Removal WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working with or near fuel-related items. Highly flammable mixtures are always...
Diagnostics and checks (1.8L/2.0L/1.6L Zetec-E) Inspection and verification 1. Check the customer complaint. 2. Visually inspect for obvious signs of mechanical or electrical damage. Visual inspection table Mechanical...
Throttle Body (1.8L/2.0L/1.6L Zetec-E) Removal CAUTION: Do not attempt to clean the throttle body. The bore and throttle body have a special coating applied during manufacture that must not be removed. 1....
Fuel injectors (1.8L/2.0L/1.6L Zetec-E) Removal WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working with or near fuel-related items. Highly flammable mixtures are always...
Fuel Supply Manifold (1.8L/2.0L/1.6L Zetec-E) Removal WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working with or near fuel-related items. Highly flammable mixtures are always...
Fuel Pressure Regulator (1.8L/2.0L/1.6L Zetec-E) Removal WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working with or near fuel-related items. Highly flammable mixtures are always...
Diagnostics and checks (1.8 l diesel) Inspection and verification WARNING: Do not smoke or carry a lighted cigarette or open flame of any kind when working on or near fuel-related components. Highly...
Fuel injectors (1.8 l diesel) Removal All cars 1. WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working with or near fuel-related items. Highly flammable mixtures...
High pressure fuel pump (1.8 l diesel) Special tool Hand Vacuum/Pressure Pump 23-036A (416-D001) High Pressure Fuel Pump Pulley Puller 310-095 (23-067) Removal All cars 1. WARNING: Do not smoke or carry a...
Specifications (turbocharger) Tightening torque specifications Name Nm pound foot pound-inch Engine roll limiter bolt 48 35 - Nipple connection of the feed oil line - vehicles with a diesel engine of...
Description and principle of operation (turbocompressor) Cars with diesel engine 70 hp or 90 hp. Pos. Spare Part No Name 1 - Turbocharger/Exhaust Manifold The turbocharger consists of two elements: a turbine and a compressor,...
Diagnostics and checks (turbocharger) Special tool Boost pressure gauge 310 - 020 (23 - 021) Hand Vacuum/Pressure Pump 416 - D001 (23 - 036A) Operating principle - Cars with a diesel engine of 75 hp or 90...
Inspection and testing (turbocharger) NOTE: It is normal for a small amount of combustion chamber gases to leak into the engine crankcase. This gas is purged into the air intake system by the Positive...
Pinpoint tests (turbocharger) PINPOINT TEST A: NOISY TURBOCHARGER OPERATION/BLACK OR BLUE SMOKE STATES DETAILS/RESULTS/ACTIONS A1: INSPECTING TURBOCHARGER ROTOR BLADES FOR DAMAGE 1 Disconnect the air...
Turbocharger 1.8 l diesel (75 PS/90 PS) Removal All cars 1. Disconnect the ground cable from the battery. For additional information, refer to Section 414-01. 2. Remove the air cleaner. Refer to Section 303-12...
Turbocharged 1.8L Diesel with Fuel Injection Removal 1. Disconnect the ground cable from the battery. For additional information, refer to Section 414-01. 2. Remove the air cleaner. Refer to Section 303-12 for...
Diagnostics and checks (diesel with fuel injection) Inspection and verification WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working on or near fuel-related components. Highly...
Fuel injectors (diesel fuel injection) Special tool Worldwide Diagnostic System (WDS) 418-F224 General equipment: Pneumatic vacuum gun. Name Specification Grease for nipple connection of high pressure fuel...
Fuel Supply Manifold (Diesel Fuel Injection) Special tool Worldwide Diagnostic System (WDS) 418-F224 General equipment: Pneumatic vacuum gun. Name Specification Grease for nipple connection of high pressure fuel...
Fuel pump (diesel with fuel injection) Special tool Worldwide Diagnostic System (WDS) 418-F224 Hand Vacuum/Pressure Pump 23-036A (416-D001) General equipment: Engine vacuum cleaner. Name Specification...
Fuel return line with Venturi nozzle General equipment: Pneumatic vacuum gun. Removal All cars WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working with or near...
Specifications (Duratec ST 2.0L) Tightening torque specification Name Nm pound-foot pound-inch Throttle body 7 - 62 Fuel manifold bolts 10 - 89 Spark Plug Cover Bolts 8 - 71
Description and operating principle (Duratec ST 2.0 l) Fuel supply and controls Pos. Spare Part No Name 1 – Fuel pressure sensor 2 – Fuel manifold 3 – Injector mounting clamp 4 – Nozzle O - rings 5 – Fuel injector 6 – Fuel...
Throttle Body (Duratec ST 2.0L) Removal CAUTION: Do not attempt to clean the throttle body. The bore and throttle plate have a special coating applied during manufacture that must not be removed. 1....
Fuel Delivery System Wiring Harness (Duratec ST 2.0L) Removal 1. Disconnect the ground cable from the battery. For additional information, refer to Section 414-01. 2. Remove the ignition coil cover. 1. Disconnect the...
Fuel Supply Manifold (Duratec ST 2.0L) Removal WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working with or near fuel-related items. Highly flammable mixtures are always...
Description and operating principle (1.6L Duratec) Cars with 1.6L Duratec engine Pos. Spare Part No Name 1 Fuel injection system wiring harness 2 Fuel injector 3 Fuel pressure regulator 4 Throttle body 5 Fuel manifold
Diagnostics and checks (1.6L Duratec) Inspection and verification 1. Check the customer complaint. 2. Visually inspect for obvious signs of mechanical or electrical damage. Visual inspection table Mechanical...
Throttle Body (1.6L Duratec) Removal CAUTION: Do not attempt to clean the throttle body. The bore and throttle plate have a special coating applied during manufacture that should not be removed. 1....
Fuel Delivery System Wiring Harness (1.6L Duratec) Removal 1. Disconnect the fuel injection system wiring harness plug connector. 2. Disconnect the camshaft position sensor (CMP) plug connector. 3. Disconnect the fuel...
Fuel Supply Manifold (1.6L Duratec) Removal 1. Relieve the fuel pressure. Refer to Section 310-00 for additional information. 2. Disconnect the positive crankcase ventilation (PCV) hoses from the intake...
Diagnostics and testing of the fuel supply system Special tool Hand Vacuum/Pressure Pump 416-D001 (23-036A) Inspection and verification 1. Check the customer complaint. 2. Perform a visual inspection for obvious signs...
Pinpoint tests of the fuel supply system PINPOINT TEST A: AIR PENETRATION INTO FUEL LINES - 75 HP OR 90 HP DIESEL VEHICLES. STATES DETAILS/RESULTS/ACTIONS WARNING: Do not smoke or carry a lighted cigarette or...
Relieving pressure in the fuel supply system 1. WARNING: Do not smoke or carry a lighted cigarette or open flame of any kind when working on or near fuel-related components. Highly flammable mixtures are always...
Quick coupling — disconnection and connection Disconnection WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working on or near fuel-related items. Highly flammable vapors are always...
Emptying the fuel tank Drain WARNING: Do not smoke or carry a lighted cigarette or open flame of any kind when working on or near fuel-related components. Highly flammable mixtures are always...
Spring Lock Couplings — Disconnecting and Connecting Special tool Spring Lock Coupling Release Tool (3/8", Yellow) 310-D004 (23-039) Tool for disconnecting the coupling with a spring lock (1/2", green color) 310-D005...
Fuel tank and fuel lines Tightening torque specification Name Nm Pound foot Pound-inch Fuel tank clamp bolt 25 18 - Exhaust Pipe Flange Bolts 48 35 - Fuel filler line bolts 9 - 80 Fuel tank vent...
Fuel tank — removal and installation Removal WARNING: Do not smoke or allow lighted cigarettes or any open flame when working with or near any fuel containing components. Highly flammable mixtures are...
Fuel Pump Module — Removal and Installation Special tool Fuel tank sensor key 310-069 (23-055) Removal 1. Remove the fuel tank. For more information, refer to the Fuel Tank chapter in this section. 2. Disconnect...
Fuel tank filler pipe — removal and installation Removal 1. WARNING: Do not smoke or allow lighted cigarettes or any open flame when working with or near any fuel containing components. Highly flammable mixtures are...
Fuel filter — removal and installation Removal 1. WARNING: Do not smoke or allow lighted cigarettes or any open flame when working with or near any fuel containing components. Highly flammable vapors are...
Fuel filter (1.8 l diesel) — removal and installation Removal 1. WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working with or near fuel-related items. Highly flammable vapors are always...
Inertial Fuel Shutoff Switch (IFS) Removal 1. Remove the right front door opening trim panel. 2. Disconnect the electrical connector. 3. Remove the fuel inertia switch. Installation 1. NOTE: Make sure the...
Acceleration control (accelerator) The acceleration control system consists of an accelerator pedal and an accelerator cable. The driver, pressing the accelerator pedal, installed in the passenger...
Accelerator pedal — removal and installation Removal 1. Remove the footwell trim panel. 2. Disconnect the accelerator cable from the pedal. 3. Remove the pedal and bracket. Installation 1. Install the elements back...
Speed control Tightening torque specification Name Nm Pound foot Pound-inch Speed control actuator nuts 6 - 53 Speed Control Switch Bolts 5 - 44 Pos. Spare Part No Name 1 - Speed...
Speed control diagnostics and tests Inspection and verification 1. Check the validity of the customer's complaint by using the system. 2. Visually inspect for obvious signs of mechanical and electrical...
Pinpoint speed control tests PINPOINT TEST A: SPEED CONTROL SYSTEM NOT WORKING STATES DETAILS/RESULTS/ACTIONS A1: CHECKING THE OPERATION OF THE SOUND SIGNAL 1 Press the horn switches. • Does the...
Speed control cable Removal 1. Remove the air cleaner outlet pipe. 2. Disconnect the speed control cable from the throttle body. 3. Disconnect the speed control cable from the bracket. 4....
Speed control cable (Duratec ST 2.0L) Removal 1. Release the speed control cable from the clamp. 2. Disconnect the speed control actuator cable cover. 3. Disconnect the speed control cable from the speed...
Speed control system switch Removal 1. Remove the driver air bag module. Refer to Section 501-20B for additional information. 2. Disconnect the speed control switch electrical connector. 3. Remove...