Engine Controls - Remove/install/overhaul - 2.5L: Removal & Installation Ford Contour I рестайлинг

Removal & Installation

Disconnect negative battery cable. Remove any component necessary to gain access to PCM. Loosen PCM connector retaining bolt (if equipped). Unplug harness connector from PCM. Remove 2 PCM mounting bolts. Remove PCM cover and PCM. To install, reverse removal procedure.

PCM LOCATIONS

CKP sensor is located on front cover near crankshaft pulley. Disconnect negative battery cable. Raise and support vehicle. Remove splash shield from right side of engine compartment. Remove electrical connector from sensor. Remove mounting screw and CKP sensor. To install, reverse removal procedure.

Removal (Spring Lock Coupling)

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-131322-S35275154102001121400000). 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 4)
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 4

Installation

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 NEW "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 4)

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 5) 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 5

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 6)
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 6

CMP sensor is located on front of forward cylinder head. Disconnect negative battery cable. Disconnect CMP sensor harness connector. Remove CMP sensor retaining screw and CMP sensor. (Scheme 7) Ensure "O" ring is properly located and in good condition. To install, reverse removal procedure.

Scheme 7

Removal (With Returnless Fuel System)

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-131322-S35275154102001121400000) . Remove fuel tank.
2. Using the Wrench, Sender Unit, Fuel Tank 310-065A (23-054), remove the fuel pump locking ring.
3. Remove the fuel pump module. Rotate the pump counterclockwise to remove.
4. Remove and discard the O-ring seal.

Install a new O-ring seal and locking ring. To install, reverse the removal procedure.

Removal (Without Returnless Fuel System)

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-131322-S35275154102001121400000) . Remove fuel tank.
2. Disconnect the fuel line. Depress the clips to release the line. Disconnect the fuel line.
3. Remove the fuel tank pressure sensor. Depress the sensor to release. Rotate the sensor to remove.
4. Using the Wrench, Sender Unit, Fuel Tank 310-065, remove the fuel pump locking ring.
5. Remove the fuel pump module. Rotate the pump counterclockwise to remove.
6. Remove and discard the O-ring seal.

Install a new O-ring seal and locking ring. To install, reverse the removal procedure.

Removal

1. Relieve the fuel system pressure. For additional information, refer to
2. Raise and support the vehicle.
3. Disconnect the fuel lines from the fuel filter.
4. Remove the fuel filter.

Note. Observe the direction of flow indicator.

To install, reverse the removal procedure.

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-131322-S35275154102001121400000) . Remove air cleaner housing and air ducts. Disconnect negative battery. Remove upper intake manifold. See «UPPER INTAKE MANIFOLD»(ref-131322-S21124098162001121400000) .
2. Disconnect fuel injector wiring. Disconnect vacuum hose from pressure regulator. Disconnect fuel pressure and return lines from fuel rail. Remove fuel rail mounting bolts.
3. Remove Intake Manifold Runner Control (IMRC) cable end and cable bracket. Remove fuel rail with injectors attached.

Lubricate NEW "O" rings and install on injectors. Replace injector-to-manifold seals. To complete installation, reverse removal procedure.

1. If removing fuel pressure regulator while fuel rail assembly is still installed on engine, release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-131322-S35275154102001121400000) .
2. Remove vacuum line at pressure regulator. Remove pressure regulator mounting screws or retaining clip. 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 or reinstall retaining clip.

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.

1. Disconnect negative battery cable. Remove water pump pulley shield. Remove air cleaner housing and outlet tube.
2. Disconnect accelerator and speed control cables. Remove EGR valve. Disconnect necessary vacuum hoses from upper intake manifold and EGR vacuum regulator valve.
3. Disconnect PCV hose. Disconnect necessary electrical connectors from upper intake manifold. Loosen upper intake manifold bolts in reverse of tightening sequence. (Scheme 8)

Use NEW gaskets. Tighten upper intake manifold bolts in sequence (in 2 steps) to specification. (Scheme 8) See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

Scheme 8

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 specification. See TORQUE SPECIFICATIONS .

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.