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Fuel Pump > < Fuel Charging Wiring Harness

Mondeo 2001 (10.2000-02.2007)

Fuel Charging and Controls - 1.8L Duratec-SCi (MI4) - Fuel Injection Supply Manifold Mondeo 2001 (10/2000-02/2007)
Removal and Installation

Special Tool(s)

Remover/Installer, Cooling Hose Clamp

303-397 (24-003)

Materials
Name
Specification
Engine Oil - 5W-30
WSS-M2C153-G
WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:Do not carry out any repairs to the fuel injection system with the engine running. The fuel pressure within the system can be as high as 120 bar. Failure to follow this instruction may result in personal injury.
WARNING:
WARNING:Wait at least one minute after the engine stops before commencing any repair to the fuel injection system. Failure to follow this instruction may result in personal injury.
CAUTION:
CAUTION:Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfunction.
CAUTION:
CAUTION:Do not disassemble or clean inside the fuel injection supply manifold, even with an ultrasonic cleaner.
  1. Release the fuel system pressure. For additional information, refer to Section  310-00 Fuel System - General Information.
  1. Drain the cooling system. For additional information, refer to Section  303-03 Engine Cooling.

  1. Remove the engine upper cover.

  1. Using the special tool, detach the positive crankcase ventilation (PCV) hose from the valve cover.

  1. Remove the air cleaner outlet pipe.

  1. Remove the ground connector from the fuel supply and fuel return line cover.
  1. Remove the intake manifold. For additional information, For additional information, refer to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine / 303-01E Engine.

  1. Remove the fuel supply and fuel return line cover.

  1. Loosen the high-pressure fuel supply line union.

  1. Disconnect the coolant outlet connector lower coolant hose.

  1. Remove the coolant outlet connector retaining bolt.

  1. Disconnect the fuel return line quick release coupling from the fuel injection supply manifold. For additional information, refer to Section  310-00 Fuel System - General Information.
  1. Install blanking caps to the open ports on the fuel return line and the fuel injection supply manifold.

  1. Remove the fuel supply line from the fuel injection supply manifold.
    • Discard the O-ring seal.
  1. Install blanking caps to the open ports on the fuel supply line, fuel injection supply manifold and fuel pump.

16. Remove the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Fuel rail pressure (FRP) sensor electrical connector
2
-
fuel injectors electrical connectors
3
-
Fuel charging wiring harness
See Removal Detail
4
-
Fuel injection supply manifold retaining bolts
See Installation Detail
5
-
Fuel injection supply manifold
See Installation Detail
6
-
Fuel injector O-ring seals
7
-
Fuel injector O-ring seal support discs
See Installation Detail

17. To install, reverse the removal procedure.

NOTE:
NOTE:Discard all blanking plugs.

Removal Details

Item 3 : Fuel charging wiring harness

  1. Detach the fuel charging wiring harness from the fuel injection supply manifold.

Installation Details

Item 7 : Fuel injector O-ring seal support discs
  1. Inspect the the fuel injector O-ring seal support disc for damage. Install a new support disc as necessary (fuel injector shown removed for clarity).

Item 5 : Fuel injection supply manifold

  1. CAUTION:
    CAUTION:Do not use excessive force to install the fuel injectors to the fuel injection supply manifold. Failure to follow this instruction may result in damage to the fuel injector seals.
    Using suitable engine oil, lubricate the new fuel injector O-ring seals to assist the installation of the fuel injection supply manifold.

Item 4 : Fuel injection supply manifold retaining bolts
  1. Tighten the fuel injection supply manifold retaining bolts in the sequence shown.

Fuel Pump > < Fuel Charging Wiring Harness