ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

Fuel Pressure Regulator > < Fuel Charging Wiring Harness
Fuel Charging and Controls - 1.8L Duratec-DOHC (Zetec) - Fuel Injection Supply Manifold Transit/Tourneo Connect 2002.5 (06/2002-)
Removal and Installation

Special Tool(s)

Disconnect Tool, Fuel Line (5/16")

310-040

Materials
Name
Specification
Formula E Engine Oil SAE 5W-30
WSS-M2C911-A1
  1. 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 vapors 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:The fuel system remains pressurized for a long time after the ignition is switched off. The fuel pressure must be relieved before attempting any repairs. failure to follow this instruction may result in personal injury.
    Release the fuel system pressure. For additional information, refer to Section  310-00A Fuel System - General Information.
  1. Disconnect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

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

 
Item
Part Number
Description
1
-
Air cleaner outlet pipe to air cleaner retaining clamp
2
-
Air cleaner outlet pipe to throttle body retaining clamp
3
-
Air cleaner outlet pipe
4
-
Accelerator cable to throttle body

 
Item
Part Number
Description
6
-
Fuel injector electrical connectors
7
-
Fuel pressure regulator vacuum line
9
-
Fuel return line to fuel pressure regulator spring release coupling
See Removal Detail
10
-
Fuel injection supply manifold retaining bolts
11
-
Fuel injector retaining clips
12
-
Fuel injectors
13
-
14
-
Fuel pressure regulator retaining bolts
15
-
Fuel pressure regulator
16
-
17
-
Fuel injection supply manifold fuel supply pipe retaining bolts
18
-
Fuel injection supply manifold fuel supply pipe retaining clip
19
-
Fuel injection supply manifold fuel supply pipe
20
-
21
-
Fuel injection supply manifold

4. To install, reverse the removal procedure.

Removal Details

Item 5 : Accelerator cable to throttle body accelerator cable retaining bracket

  1. Rotate and detach the accelerator cable from the throttle body accelerator cable retaining bracket.

Item 8 : Fuel supply line to fuel injection supply manifold fuel supply pipe quick release coupling

CAUTION:
CAUTION:The generator must be protected from contamination. Failure to follow this instruction may cause premature failure of the generator.
  1. Protect the generator with lint-free material to prevent contamination.
  1. Disconnect the fuel supply line from the fuel injection supply manifold fuel supply pipe. For additional information, refer to Section  310-00A Fuel System - General Information.

Item 9 : Fuel return line to fuel pressure regulator spring release coupling

  1. Disconnect the fuel return line from the fuel pressure regulator. For additional information, refer to Section  310-00A Fuel System - General Information.

Installation Details

Item 20 : O-ring seal
Item 16 : O-ring seal
Item 13 : O-ring seals

CAUTION:
CAUTION:Do not use silicone grease to lubricate O-ring seals as it will block the fuel injectors.
  1. Lubricate the seals with clean engine oil to assist with installation.

Fuel Pressure Regulator > < Fuel Charging Wiring Harness