Removal and installation of fuel injection system components (Mondeo 1 and 2)

Warning: Before you begin, read the warning in paragraph 1 of this chapter.

Electronic control unit

Warning: The ECU is a fragile device. It must not be dropped, shaken or hit, and it must be protected from moisture and sudden temperature changes. Do not touch the connector pins, as they may contain static electricity, which, if shorted, will damage the electronic components inside the ECU.

Note: When replacing the EEC-V fuel injection control system, be aware that it must be programmed for your engine using the special FDS 8000 equipment. If this is not done, the system will remain in the "limited controllability" mode and the engine will not realize its potential in terms of power and economy.

Removal

1. Disconnect the negative battery cable (Chapter 5A).

2. Carefully remove the power steering fluid reservoir by lifting it and releasing it from the retainer on the suspension support. Unscrew the ECU mounting bolt and disconnect the electrical connector (see Fig. 14.2, a-e).









3. From inside the passenger compartment, unscrew the bolt and remove the support bracket (see Fig. 14.3).





4. Then lift the ECU to release it from the bulkhead bracket and pull out the unit (see Fig. 14.4).

Installation

5. Installation - in the reverse order of removal. In any case, when the battery is disconnected, the parameters related to idle speed control, as well as other operating parameters, must be re-entered into the electronic memory of the control unit. The ECU performs the entry of such parameters independently, but until they are entered, the engine may starve, intermittently or run erratically at idle or fail to achieve its intended characteristics. To enter these parameters into the ECU in the learning mode, start the engine and bring it to a speed that has minimal differences from idle speed. Keep it at this mode until it warms up to normal operating temperature, and then let it run at 1200 rpm for about two minutes. Then drive the distance you require. When you have driven about eight km using various driving modes, the learning process is complete.

Air flow meter

Removal

6. Disconnect the negative battery cable (Chapter 5A).

7. On models with 4-cylinder engines, disconnect the electrical connector by releasing it from the retainer. Release the retainers and remove the air cleaner cover. Then release the two small retainers and separate the flow meter from the cover. Release the clamp securing the flow meter to the resonator hose and remove the flow meter (see Fig. 14.7, a, b).



8. On models with V-6 engines, remove the air cleaner (paragraph 4). Unscrew the flow meter bolts and remove it from the air cleaner cover.

Installation

9. Installation - in the reverse order of removal. It is necessary to correctly install the flow meter and the air cleaner cover and securely fasten them to prevent air leaks.

Crankshaft Position/Speed Sensor

Removal

10. Disconnect the negative battery cable (Chapter 5A).

11. Apply the parking brake. Raise the front end and place it on supports.

12. On 4-cylinder models, remove the front left wheel arch liner. On V6 models, remove the front right wheel arch liner.

13. Disconnect the wiring from the sensor (see Fig. 14.13.a,b).



14. Remove the screws and remove the sensor.

Installation

15. Installation - in the reverse order of removal.

Camshaft Position Sensor

Removal

16. On models with 4-cylinder engines, the sensor is installed on the cylinder head at the rear left. On models with V-shaped 6-cylinder engines, the sensor is installed on the valve timing cover on the right (see Fig. 14.16).





17. To access the sensor, remove the air flow meter and (on models with 4-cylinder engines) the resonator (see Fig. 14.17). Release the injection and drain fuel lines from the clamps.



18. Disconnect the sensor electrical connector by releasing its retainer. Unscrew the screw and remove the sensor from the cylinder head. Note that some oil may leak from the sensor.

Installation

19. Installation - in the reverse order of removal, taking into account the following:

• a) Lubricate the O-ring (round cross-section) of the sensor with technical petroleum jelly or clean motor oil.
• b) Install the sensor into the cylinder head and remove excess grease. Then tighten it.
• c) Tighten the screw to the required torque.

Coolant temperature sensor

20. See Chapter 3.

Intake Air Temperature Sensor

Removal

21. To access the sensor, remove the air flow meter and (on models with 4-cylinder engines) the resonator (see Fig. 14.21).



22. Disconnect the sensor electrical connector by releasing it from the retainer. Then unscrew the sensor from the resonator, intake air duct or air cleaner housing.

Installation

23. Installation - in the reverse order of removal. Tighten the sensor to the required torque, avoiding excessive force when tightening, since its tapered thread can damage the component into which the sensor is screwed.

Throttle potentiometer

Removal

24. On models with 4-cylinder engines, remove the intake air duct chamber (paragraph 4). On V6 models, remove the water pump pulley shield. If necessary, remove the positive crankcase ventilation hose from the intake air duct.

25. Disconnect the potentiometer electrical connector by releasing the connector lock. Unscrew the mounting screws and remove the unit from the throttle body (see Fig. 14.25, a, b). Do not turn the potentiometer slider beyond its normal working stroke to avoid damaging the unit.

Installation

26. Installation - in the reverse order of removal, taking into account the following:

• a) Align the potentiometer slider with the throttle shaft (with the throttle closed) and position the potentiometer housing so that the screws fit freely into the throttle housing.
• b) Tighten the screws evenly, without overtightening them, so as not to damage the potentiometer housing.

Speedometer sensor

27. On models produced before 1997, this sensor is installed on the base of the speedometer drive cable and is removed together with the speedometer drive gear (see Fig. 14.27). On later models, it is installed in the same place, but the cable is missing due to the use of an electronic speedometer. See Chapter 7A or 7B.

Power steering pressure sensor

Removal

28. Disconnect the sensor electrical connector by releasing it from the retainer. Then unscrew the sensor (see Fig. 14.28).



29. Before removing, place rags around the sensor to catch any drips. If there is a sealing washer under the sensor, inspect it for wear or damage and replace if necessary.

Installation

30. Installation - in the reverse order of removal. Securely tighten the sensor. Then top up the tank (chapter 1) to compensate for leaks from the system and bleed air through the valve (see Chapter 10).

Throttle Body (4-Cylinder Models)

Removal

31. Disconnect the negative battery cable (Chapter 5, paragraph 1).

32. Remove the intake air duct chamber (paragraph 4).

33. Disconnect the accelerator cable from the throttle linkage. Disconnect the cruise control actuator cable (if equipped) (see Chapter 12).

34. Disconnect the large electrical connector (closest to the fuel pressure regulator) by releasing its wire retainer. Disconnect the throttle potentiometer electrical connector in the same manner.

35. Tag and then disconnect all vacuum hoses from the throttle body.

36. Remove the throttle body mounting screws (see Fig. 14.36). Then remove the body and gasket from the intake manifold. Discard the gasket. It should always be replaced after removal.



37. Using a soft brush and cleaning agent, thoroughly clean the outer surface of the throttle body, then blow out all passages with compressed air.

Caution: Do not clean the throttle body bore, the throttle body itself, or the throttle potentiometer with solvent or a scraper, but only wipe them thoroughly with a soft, clean cloth.

Installation

38. Installation - in the reverse order of removal. Install a new gasket and tighten the housing screws to the required torque.

Throttle body (models with V-shaped 6-cylinder engines)

Removal

39. Disconnect the negative battery cable (Chapter 5, paragraph 1).

40. Remove the air cleaner and intake duct (paragraph 4). Also remove the coolant pump pulley shield.

41. Disconnect the throttle potentiometer electrical connector and disconnect the wiring from the rod. Move the wiring to the side.

42. Disconnect the accelerator cable from the throttle linkage. Disconnect the cruise control actuator cable (if equipped) (see Chapter 12).

43. Remove the bolts and nut securing the throttle body. Then remove the body and gasket from the intake manifold. Discard the gasket. It should always be replaced after removal.

44. Using a soft brush and cleaning agent, thoroughly clean the outer surface of the throttle body, then blow out all passages with compressed air.

Caution: Do not clean the throttle body bore, the throttle body itself, or the throttle potentiometer with solvent or a scraper, but only wipe them thoroughly with a soft, clean cloth.

Installation

45. Installation - in the reverse order of removal. Install a new gasket and tighten the bolts and housing nut to the required torque.

Fuel Rail and Fuel Injectors (4-Cylinder Models)

Removal

Note: For simplicity and to ensure maximum cleanliness during assembly, this procedure involves removing the fuel rail assembly along with the fuel injectors and pressure regulator. The fuel injectors can then be serviced individually on a clean work surface.

The fuel injectors can also be removed and installed individually once you have relieved the fuel system pressure and disconnected the battery.

46. Release residual pressure in the fuel system (paragraph 2) and equalize the pressure in the tank by removing the cap of its neck.

Warning: Remember that after releasing residual pressure, fuel remains in the system components and take precautions before disconnecting them.

47. Disconnect the negative battery cable (Chapter 5, paragraph 1).

48. Remove the intake air duct chamber (paragraph 4),

49. For better access, the accelerator cable can be disconnected from the throttle linkage. Also disconnect the cruise control actuator cable (Chapter 12) (if equipped).

50. Disconnect the four fuel injector electrical connectors by releasing them from the wire retainers. On 7/1997 models, the wiring harness is routed in a channel.

51 Disconnect the injection and drain pipes by disconnecting the quick-release couplings near the brake booster. Then detach the fuel hoses from the intake manifold. Remove any fuel leaks with a rag (see Fig. 14.51).

Note: Do not disconnect the threaded couplings installed on the fuel line fittings unless absolutely necessary. They are sealed during manufacture. Quick-release couplings are sufficient for servicing.

52. Disconnect the crankcase ventilation hose from the fitting on the cylinder head cover (on models produced before 07.1997) and the vacuum hose from the fuel pressure regulator.

53. Unscrew the three bolts securing the fuel line and remove it, carefully separating it from the intake manifold so that the remaining fuel flows into a clean container (see Fig. 14.53, a, b). Note that on models produced since 07.1997, the design of the fuel line has been changed, and the injectors are installed directly in the intake manifold. Pay attention to the seals between the protrusions of the line and the manifold. After removing the line, they should always be replaced.



54. Carefully secure the fuel line in a vice using soft jaws. On models produced before 07.1997, unscrew the two mounting bolts on each fuel injector and remove the injectors. On later models, pull back the clamps and pull the injectors out of the fuel line. Place each injector in a clean, labeled container (see Fig. 14.54, a, b).





55. If you are replacing the injector(s), discard the old injector, the line flange seal, and the O-rings. If you are replacing only the injector O-rings due to leakage and will be reinstalling the same injector in its place, remove the old line flange seal as well and discard it.

56. The subsequent operations of checking fuel injectors are beyond the capabilities of the car owner. If you doubt the serviceability of the injector(s), check it at the dealers.

Installation

57. Installation - in the reverse order of removal, taking into account the following:

• a) Lubricate each line flange seal and O-ring with clean engine oil.
• b) On models produced before 07/1997, install each injector into the recess in the line so that the mounting lug on the injector head fits into the slot in the line. Tighten the bolts to the specified torque.
• c) Connect and secure the quick-release couplings of the fuel injection and drain lines (paragraph 3).
• d) Secure the ventilation hose, vacuum hose and wiring with the necessary fasteners and ties, routing them accordingly.
• d) Finally, turn the ignition on and off five times to start the fuel pump and restore pressure in the system (without cranking the engine). Before starting the engine, check for fuel leaks in the area of the connections you disassembled.

Fuel line and fuel injectors (V-6 engine models)

Removal

58. Eliminate residual pressure in the fuel system (paragraph 2) and equalize the pressure in the tank by removing the cap of its neck.

59. Disconnect the negative battery cable (Chapter 5, paragraph 1).

60. Remove the upper section of the intake manifold (chapter 2B).

61. Disconnect the wiring from the injectors and move it to the side (see Fig. 14.61, a, b).

Models produced before 07.1997

62. The injectors can be removed by first unscrewing the clamp bolts and removing the clamps. Place each injector in a clean, labeled container. The injectors can also be removed together with the fuel line.

63. To remove the line, loosen the clamps and disconnect the fuel hoses from the line. Also disconnect the vacuum hose from the fuel pressure regulator. Then unscrew the line bolts and remove it from the lower section of the intake manifold.

Models produced since 07.1997

64. Disconnect the vacuum hose from the fuel pressure regulator (see Fig. 14.64).



65. Disconnect the intake system drive rod with the resonator by disconnecting the cable and its casing (see Fig. 14.65, a, b).



66. Disconnect the fuel supply and outlet lines by releasing their quick-release connections (see Fig. 14.66, a-c).





67. Unscrew the bolts and remove the fuel line from the lower section of the intake manifold (see Fig. 14.67, a-c). The injectors can be removed together with the line or left in the intake manifold.





68. Remove the injectors from the lower section of the intake manifold or line and place them in a clean container.

All models

69. Remove and discard all O-rings. Further testing of fuel injectors is not possible for the vehicle owner. If you are in doubt about the serviceability of the injector(s), contact the dealer.

Installation

70. Installation - in the reverse order of removal, taking into account the following:

• a) Lubricate the new O-rings with clean engine oil. Install the injectors on the lower section of the intake manifold, then install the fuel line on them (see Fig. 14.70).
• b) Tighten the line bolts to the specified torque.
• c) Finally, turn the ignition on and off five times to start the fuel pump and restore pressure in the system (without cranking the engine). Before starting the engine, check for fuel leaks in the area of the connections you disassembled.

Fuel pressure regulator

Removal

71. Release residual pressure in the fuel system (paragraph 2) and equalize the pressure in the tank by removing the cap of its neck.

Warning: Remember that after releasing residual pressure, fuel remains in the system components and take precautions before disconnecting them.

72. Disconnect the negative battery cable (Chapter 5, paragraph 1).

73. On models with 4-cylinder engines produced before 07/1997, remove the air intake duct chamber (paragraph 4) and disconnect the vacuum hose from the regulator. Unscrew the two regulator mounting bolts and, having placed rags around it to absorb the leaking fuel, remove the regulator (see Fig. 14.73). On models with 4-cylinder engines produced since 07.1997, you also need to disconnect the fuel drain hose and release it from the retainer. Remove the O-ring. Remove any fuel leaks with a clean rag.



74. On pre-7/97 V6 models, remove the manifold as above. On later models, remove the upper section of the intake manifold. Disconnect the vacuum hose from the regulator. Remove the two regulator mounting bolts and, placing rags around the regulator to absorb any leaking fuel, remove the regulator. Remove the O-ring. Wipe up any fuel leaks with a clean rag.

Installation

75. Installation - in the reverse order of removal, taking into account the following:

• a) Whenever the regulator is removed, always replace the O-ring. Lubricate the new O-ring with clean engine oil.
• b) Install the regulator into the recess in the fuel line and tighten the bolts to the required torque.
• c) Finally, turn the ignition on and off five times to start the fuel pump and restore pressure in the system (without cranking the engine). Before starting the engine, check for fuel leaks in the area of the connections you disassembled.

Idle speed control valve

Removal

76. Disconnect the negative battery cable (Chapter 5, paragraph 1).

77. On models with 4-cylinder engines, lift the front end and place it on supports (see Fig. 14.77).

Warning: Do not work under a vehicle that is supported only by a jack!

78. Disconnect the valve electrical connector (see Fig. 14.78).



79. Remove the two mounting bolts (on models with 4-cylinder engines) or nuts (on models with V-shaped 6-cylinder engines) and remove the valve from the intake manifold (see Fig. 14.79). Remove the gasket.



80. Since the valve components are not supplied separately and in case of a malfunction the entire unit must be replaced, you can try flushing the passages with a carburetor cleaner or something similar. This will not take much time and may lead to the elimination of the malfunction.

Installation

81. Installation - in the reverse order of removal, taking into account the following:

• a) Thoroughly clean the mating surfaces. Always install a new gasket after removing the valve.
• b) Tighten the bolts evenly to the specified torque.
• c) Immediately after connecting the wiring and battery, start the engine and set it to idle. After it warms up to normal operating temperature, make sure that the idle speed has not changed and that there are no air leaks. Turn on all electrical consumers (headlights, rear window heater) and make sure that the idle speed remains within the specified value.

Idle speed increase valve

Removal

82. If necessary, the air intake duct chamber can be removed to improve access (paragraph 4).

83. Disconnect the negative battery cable (paragraph 1 of chapter 5).

84. Disconnect the valve electrical connector. Unfasten the valve from the bulkhead, then disconnect the vacuum hoses and remove the valve (see Fig. 14.84).

Installation

85. Installation - in the reverse order of removal.

(The text is available on the specified website info portal: www.FordBook.ru)