Engine Controls - Remove/install/overhaul - 2.0L: Removal & Installation Ford Contour I

Removal

1. Remove high tension leads and distributor cap. Rotate crankshaft in direction of normal rotation until piston No. 1 is at TDC of compression stroke. Disconnect negative battery cable.
2. Ensure timing marks are aligned. Disconnect distributor wiring from harness. Mark distributor rotor-to-housing and housing-to-engine position for installation reference. Remove distributor hold-down bolt(s) and clamp. Some engines may be equipped with a security-type distributor hold-down bolt.
3. If necessary, use Distributor Hold-Down Wrench (T82L-12270-A) to remove bolt. Remove distributor. Inspect distributor "O" ring and replace if necessary.

Installation

1. Ensure engine is at TDC of compression stroke. Rotate distributor rotor so reference marks nearly align. Insert distributor drive into engine.
2. When installing distributor, rotor will rotate. Ensure reference marks are aligned when distributor is fully engaged in engine. To complete installation, reverse removal procedure. Set base ignition timing. See the «ADJUSTMENTS - 2.0L»(ref-23134) article.

Removal & Installation

CKP sensor is located at rear of engine block near flywheel. Disconnect negative battery cable. Raise and support vehicle. Remove electrical connector from sensor. Remove mounting bolt and CKP sensor. To install, reverse removal procedure.

Removal (Spring Lock Coupling)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Using Spring Lock Coupling Remover (D87L-9280-A for 3/8" or D87L-9280-B for 1/2"), remove retaining clip from coupling. Place remover over coupling so protrusion is positioned on cage opening side of coupling. (Scheme 1)
2. Close remover over coupling. Push remover into cage opening to release female fitting from garter spring. Separate male and female halves of coupling. Remove tool from disconnected spring lock coupling.

Scheme 1

1. Ensure garter spring in cage of male fitting is not damaged. Replace if necessary. Clean all dirt from both pieces of coupling. Check "O" rings for damage, and replace using proper fuel resistant "O" rings (if necessary).
2. Lubricate "O" rings and inside of female fitting with clean engine oil. Snap fitting together. Install retaining clip onto coupling. Ensure horseshoe portion of clip is over coupling. DO NOT install retaining clip over rubber fuel line. (Scheme 1)

Removal (Hairpin Clip Fitting)

Hairpin clip type fittings are used on 5/16" and 3/8" fuel lines. To disconnect fuel lines, remove hairpin clip from fitting. (Scheme 2) Spread each clip leg about 1/8" to disengage body. While pulling lightly on triangular end of clip, push legs into fitting. Work assembly clear of tube and fitting. Pull fitting and steel line in axial direction. Use twisting motion to pull fitting loose.

With triangular portion pointing away from fitting opening, insert clip into any 2 adjacent openings. Install clip to fully engage body. Clean end of fitting. Align fitting and tube axially, and push fitting onto tube end. When fitting is engaged, a click will be heard.

Scheme 2

Removal & Installation (Duck-Bill Type Fitting)

1. Duck-bill fittings are used on 1/2" and 1/4" fuel lines. Align slot on Disconnect Tool (T82L-9500-AH) with either tab on clip (90 degrees from slots on die of fitting) and insert tool. (Scheme 3)
2. Holding tool and tube in one hand, pull fitting away from tube. To install, reverse removal procedure. Pull on fitting to ensure it is fully engaged.

Scheme 3

1. Release fuel pressure. Remove rear seat cushion. Remove plastic grommet from floor pan. Disconnect fuel pump module connector.
2. Clean area to prevent contamination in fuel tank. Disconnect fuel lines from fuel pump module by squeezing tabs on fuel line together and carefully pulling fuel lines from fuel pump module.
3. Using Fuel Tank Sender Wrench (D84P-9275-A), turn retainer ring counterclockwise and remove retainer ring. Remove fuel pump module and cover opening.

Ensure fuel pump and mounting surface is clean. Lubricate new "O" ring with suitable grease. Carefully install fuel pump module into fuel tank. To complete installation, reverse removal procedure. Pressurize fuel system and check for leaks.

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Remove air intake resonators. Disconnect fuel supply and return lines. See FUEL LINE CONNECTOR. Remove wiring harness from injectors.
2. Disconnect vacuum line from fuel pressure regulator. Remove fuel rail mounting bolts. Remove fuel rail assembly with injectors. To disengage injectors from fuel rail, twist and pull injector. Remove injector clip.

Position new "O" rings onto fuel injectors. Lightly lubricate "O" rings with clean engine oil. To complete installation, reverse removal procedure. Ensure injectors are properly seated. Tighten fuel rail bolts to specification. See TORQUE SPECIFICATIONS.

1. If removing fuel pressure regulator while fuel rail assembly is still installed on engine, release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE.
2. Remove vacuum line at pressure regulator. Remove pressure regulator mounting screws. Remove pressure regulator assembly, gasket and "O" ring.
3. To install, ensure sealing surfaces are clean. Lubricate new "O" ring with clean engine oil. Install new "O" ring and gasket on regulator. Install fuel pressure regulator on fuel rail assembly, and tighten screws.

Remove fuel rail from intake manifold. See FUEL RAILS. Remove fuel injectors from fuel rail by rocking injectors while pulling injector from fuel rail. Lubricate new "O" rings with clean engine oil. Install new "O" rings on injectors. Inspect injector "plastic hat" (covering the injector pintle) and washer for deterioration. Replace as necessary.

Disconnect negative battery cable. Remove throttle body air duct. Disconnect throttle cables. Disconnect electrical connectors as necessary. Disconnect vacuum and coolant hoses as necessary. Remove throttle body bolts/nuts. Remove throttle body and gasket.

Clean and inspect gasket mating surfaces. Install new throttle body gasket. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Check and top-off cooling system.

The oxygen sensor is equipped with a permanent pigtail, which must be protected when sensor is removed. Ensure sensor is free of contaminants, and avoid using cleaning solvents of any type. Sensor may be difficult to remove when engine temperature is less than 120°F (48°C). Always use anti-seize compound on threads prior to installation. Tighten sensor to 30 ft. lbs. (41 N.m).

Remove distributor cap, if necessary. Disconnect TP sensor from wiring harness. Mark throttle body and TP sensor for reassembly reference. Remove mounting screws and TP sensor. To install, align tangs on TP sensor with blades on throttle shaft and install sensor on throttle body. Align marks on throttle body and TP sensor. Secure TP sensor to throttle assembly with retaining screws. Reconnect wiring.