Fuel Supply Manifold (1.8L/2.0L/1.6L Zetec-E)

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Withdrawal


WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations, there are always highly flammable mixtures that can ignite. Failure to follow these instructions may result in injury.


1. Relieve pressure in the fuel supply system. See Section 310-00 for more information.

2. Disconnect a wire of weight from the accumulator. See Section 414-01 for more information.

3. Disconnect the air filter outlet pipe.



4. Disconnect the accelerator cable.
  • 1. Remove the clip and disconnect the cable from the throttle body.
  • 2. Rotate the outer sheath of the cable.
  • 3. Disconnect the accelerator cable.



5. Disconnect the plug connectors for the fuel injectors.




6. Disconnect the vacuum line from the fuel pressure regulator.



7.
NOTE: Fuel line connectors are painted white or identified by a white rim. Fuel return line connectors are colored red or identified by a red rim.


Disconnect the fuel supply and return lines from the fuel pressure regulator and fuel manifold.
  • 1. Pull back on the clip to release the latch.
  • 2. Lift the connector to free the line.



8. Remove the fuel pressure regulator from the fuel manifold.




9. Remove the fuel pressure regulator O-rings and discard them as no longer needed.



10. Remove the fuel manifold.



11. Remove the fuel injectors from the fuel manifold.
  • 1. Slide the clip to release the nozzle.
  • 2. Remove the nozzle.



12. Remove the o-rings and discard them as no longer needed.




Installation


1.
WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations, there are always highly flammable mixtures that can ignite. Failure to follow these instructions may result in injury.


CAUTION: Do not use silicone grease to lubricate the O-rings, as this lubricant can clog fuel injectors.


NOTE: Install new O-rings on injectors.


NOTE: Install the O-ring on the new fuel pressure regulator.


Reinstall the elements in reverse order. To facilitate installation, apply clean engine oil to the O-rings of the fuel injectors and fuel pressure regulator.







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