Fuel injector
1 – sealing ring, 2 – input filter, 3 – anchor, 4 – coil winding, 5 – housing, 6 – sealing ring, 7 – needle valve, 8 – injector needle, 9 – electrical contact
Fuel line and injectors
Location of fuel line mounting bolts on a V6 engine
The fuel line mounting bolts are indicated by arrows.
Removal the fuel injector from the line
1 – retaining clamp, 2 – fuel line, 3 – fuel injector
Fuel injector with seals removed
1 – fuel injector, 2 – seals
Fuel supply nipple on the fuel line
The fuel supply nipple is indicated by an arrow.
OHC and V6 engines 2.8 dm³
1. Remove the ground wire from the battery.
2. On V6 engines, remove the throttle body connection cover, which is secured with three screws.
3. Remove the line connecting the air flow meter to the intake manifold.
4. On ONS engines, remove the distributor cap and set it aside. If necessary, remove the high-voltage wires.
5. Remove the connector from the idle speed valve, throttle position sensor and coolant temperature sensor.
6. On V6 engines, disconnect the throttle cable from the fuel pressure regulator bracket.
7. Slowly disconnect the vacuum and fuel lines from the fuel pressure regulator and the fuel supply connection from the fuel line.
8. Remove the overpressure chamber and throttle body.
9. Disconnect the fuel injector wires.
10. Unscrew the fuel bracket and remove it together with the fuel injectors.
11. The O-rings and retaining clips on all fuel injectors must be replaced, even if only one fuel injector must be removed from the line. The lower O-ring is installed between a thick and thin washer at the end of the injector.
12. Installation is performed in the reverse order of removal. Lubricate the sealing rings with Ford-ESEM 1C171A silicone grease. Check the CO content.
DOHC engines
13. Remove the ground wire from the battery.
14. To improve access, remove the connector from the intake air temperature sensor, high-tension wires and accelerator cable or move them to the side.
15. Slowly loosen the fuel supply connection to the line to relieve pressure in the fuel system and disconnect the hose.
16. Remove the fuel return hose (indicated by the arrow) from the line.
17. Remove the vacuum tube from the top of the pressure regulator.
18. Remove the connectors from the fuel injectors and temperature sensor.
19. Unscrew the two mounting bolts and remove the fuel line.
20. Remove the fuel injectors from the cylinder head.
21. The O-rings and retaining clips on all fuel injectors must be replaced, even if only one fuel injector must be removed from the line. The lower O-ring is installed between a thick and thin washer at the end of the injector.
22. Installation is performed in the reverse order of removal. Lubricate the sealing rings with Ford-ESEM 1C171A silicone grease. Check the CO content.
V6, 2.4 and 2.9 dm³ engines
23. Remove the ground wire from the battery.
24. Remove the line connecting the air flow meter to the intake manifold.
25. Disconnect the linkage lever from the throttle body and unscrew the 2 bolts securing the throttle cable bracket.
26. Disconnect the vacuum tubes, crankcase ventilation valve and fuel pressure regulator from the throttle body.
27. Disconnect the connectors from the throttle position sensor, engine temperature and coolant sensors, and idle speed control valve.
28. Unscrew the 6 Torx bolts that secure the air intake chamber.
29. Slowly loosen the fuel supply connection of the fuel rail to relieve pressure in the fuel system.
30. Disconnect the fuel supply line and the fuel return line.
31. Unscrew the fuel line mounting bolts and remove the line.
32. Remove the retaining clips and remove the fuel injectors from the line.
33. The O-rings and retaining clips on all fuel injectors must be replaced, even if only one fuel injector must be removed from the line. The lower O-ring is installed between a thick and thin washer at the end of the injector.
34. Installation is performed in the reverse order of removal. Lubricate the sealing rings with Ford silicone grease - ESEM 1C171A. Check the CO content.
35. On engines with an early fuel pressure regulator, connect a new fuel inlet line to the line if necessary. The new connector comes with a check catch ring and allows you to hold the connector teeth retracted. When the two halves of the connector are pressed together, the ring pops out, indicating that the connection has been made successfully.
36. Turn on the ignition 5 times without turning on the engine starter to increase the pressure in the fuel system.
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