Engine Controls - Remove/install/overhaul Ford Escort V

INTRODUCTION

Removal, overhaul and installation procedures (when available from manufacturer) are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only torque specifications may be supplied.

REMOVAL (1.9L)

Disconnect negative battery cable. Raise vehicle. Remove upper and lower damper shield assemblies. Disconnect sensor electrical connectors from wiring harness. Remove crankshaft sensor mounting screws. Remove sensor.

INSTALLATION (1.9L)

Position sensor assembly on bracket. Install 2 sensor retaining screws. Tighten screws to 40-61 INCH lbs. (4.5-7.0 N.m). Ensure sensor is not overtightened. Route sensor wiring harness, and install connector. To complete installation, reverse removal procedure.

REMOVAL (3.0L SHO)

1. Disconnect negative battery cable. Loosen A/C compressor and power steering pump tensioner pulleys. Remove belts from crankshaft pulley. Remove DIS module and intake manifold crossover tube. Remove upper timing belt cover. Disconnect sensor wiring harness at connector, and route wiring harness through belt cover.
2. Raise vehicle. Remove right front wheel. Using a universal puller, remove crankshaft pulley. Remove lower timing belt cover. Rotate crankshaft by HAND to position metal vane of shutter outside of sensor air gap. Remove crankshaft sensor mounting screws and sensor.

INSTALLATION (3.0L SHO)

1. Route sensor wiring harness through belt cover. Install sensor assembly on mounting pad, and loosely install retaining screws. DO NOT tighten screws yet.
2. Set clearance between crankshaft sensor and vane on crankshaft pulley to .03" (.8 mm). Tighten screws to 22-31 INCH lbs. (2.5-3.5 N.m). Install lower timing belt cover. Install crankshaft pulley, and tighten bolt to 112-127 ft. lbs. (152-172 N.m). To complete installation, reverse removal procedure.

REMOVAL (3.8L SUPERCHARGED)

Disconnect negative battery cable. Disconnect sensor electrical connectors from wiring harness. Raise vehicle. Remove upper and lower damper shield assemblies. Rotate by HAND to position metal vane of shutter (attached to rear of damper) outside of sensor air gap. Remove crankshaft sensor mounting screws. Remove sensor.

INSTALLATION (3.8L SUPERCHARGED)

1. Position sensor assembly on bracket. Install 2 sensor retaining screws, but DO NOT tighten. Install Crankshaft Sensor Gauge (T89P-6316-AH) to outside surface of one vane of shutter. NOTE: Gauge is magnetic and will conform to shape of vane.
2. Push sensor housing inward to contact gauge. Tighten screws to 22-31 INCH lbs. (2.5-3.5 N.m). Ensure sensor is not overtightened. Overtightening can damage crankshaft sensor.
3. Rotate crankshaft by HAND to position shutter vane with gauge outside of air gap. Remove magnetic gauge. To complete installation, reverse removal procedure.

REMOVAL & INSTALLATION (3.8L)

Disconnect negative battery cable. Disconnect camshaft sensor connector. Remove camshaft sensor mounting screws and remove sensor. To install, reverse removal procedure. Tighten camshaft sensor and mounting screws to 22-31 inch lbs. (2.5-3.5 N.m).

SYNCHRONIZER ASSEMBLY

REMOVAL (3.8L)

Disconnect negative battery cable. Remove camshaft sensor assembly. Remove synchronizer clamp and synchronizer from front engine cover.

Note. The immediate oil pump driveshaft should be removed with synchronizer assembly.

INSTALLATION

1. If plastic locator cover tool is not attached to replacement synchronizer assembly, attach Synchro Positioner Tool T89P-12200-A or equivalent as follows: Engage synchronizer vane into radial slot of tool. Rotate tool on synchronizer base until tool boss engages the base notch. The cover tool should be square and in contact with entire top surface of synchronizer base.
2. Transfer intermediate oil pump driveshaft from old synchronizer to replacement synchronizer assembly. Install synchronizer assembly so that gear engagement occurs when arrow on locator tool is pointed approximately 30 degrees counterclockwise from front face of engine block (this will locate camshaft sensor connector in pre-removal position.)
3. Install synchronizer base clamp and tighten bolt to 15-22 ft. lbs. (20-30 N.m). Remove Synchro Positioner Tool T89P-12200-A or equivalent. Install and connect camshaft sensor and negative battery cable.

Scheme 1

REMOVAL

1. Remove high tension lead and distributor cap. Align timing marks on TDC of compression stroke. Disconnect distributor wiring from harness. Note direction rotor points, and mark distributor base for installation reference.
2. On 2.2L non-turbo, mark and disconnect 2 vacuum lines from distributor diaphragm. On all models, 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. To install, reverse removal procedure. Set base ignition timing. See the ADJUSTMENTS article in this section.

OVERHAUL (ESCORT & TRACER)

Overhaul is not recommended. If distributor is defective, replace entire unit.

DISASSEMBLY (PROBE 2.2L NON-TURBO)

1. Remove distributor rotor and cover. Mark relation of drive gear to lower shaft. Remove retaining pin from drive gear. Remove retaining screw from center of signal rotor.
2. Pull signal rotor and pin from upper shaft using Two-Jaw Puller (D80L-1002-L). Note direction of arrow stamped into rotor. Disconnect two wires from pick-up coil, and mark for installation reference.
3. Remove 2 screws from pick-up coil. Remove pick-up coil. Remove 2 screws and pick-up coil mounting bracket. Remove "E" clip from stator plate. Remove 2 diaphragm mounting screws and vacuum diaphragm.
4. Remove 2 screws and stator plate. Remove upper shaft. Remove 2 retaining screws and lower shaft from distributor housing. Remove 2 "E" clips. Remove bearing and retainer from lower shaft. Remove seal from distributor housing.

REASSEMBLY (PROBE 2.2L NON-TURBO)

1. Install seal into distributor housing. Install retainer and bearing onto lower shaft. Install weights and springs onto lower shaft. Install new "E" clips. Install upper shaft onto lower shaft.
2. Ensure weight pivot pins engage advance mechanism. Install upper and lower shaft assembly into distributor housing. Install stator plate into distributor housing. Install 2 retaining screws. Install vacuum diaphragm, "E" clip and 2 attaching screws.
3. Install pick-up coil mounting plate and pick-up coil. Install pick-up wiring harness and wires. Using a socket and palm of hand, press signal rotor and pin onto upper shaft until it bottoms against shoulder of upper shaft.
4. Note direction of arrow stamped into signal rotor. Install signal rotor retaining screw. Align groove in drive gear with alignment mark on distributor housing. Install retaining pin. Install cover, gasket and rotor.

OVERHAUL (PROBE 2.2L TURBO)

Overhaul is not recommended. If distributor is defective, replace entire unit.

DISASSEMBLY (ALL OTHERS)

1. On all models except 3.8L, remove 2 TFI-IV module screws. Pull right side of module down and back up distributor mounting flange to disengage module terminals from connector in distributor base. Remove module by pulling toward flange and away from distributor. CAUTION: Attempting to remove ignition module without first moving entire module toward distributor flange will break module pins at connector.
2. On all models, hold gear, and loosen armature screws. DO NOT hold armature. Remove screws and armature. Using a felt tip pen, mark armature and gear for installation reference. Remove and discard roll pin in gear.
3. Place distributor in Axle Bearing Remover (T75L-1165-B). Press off gear using arbor press and Pinion Bearing Cone Remover (D79L-4621-A). Using emery cloth, remove burrs from distributor shaft. Remove shaft from distributor assembly.
4. On 3.8L models, remove thrust washer from distributor, and save for installation. On all models except 3.8L, remove screw and octane rod assembly. Save octane rod assembly and screw for installation. On all models, remove stator assembly screws and stator.
5. Inspect base bushing, "O" ring and distributor housing for wear, cracks or other damage. If necessary, replace "O" ring. If distributor housing or bushings are worn, replace entire distributor assembly.

Note. If distributor housing is cracked or worn, replace entire assembly.

REASSEMBLY (ALL OTHERS)

1. Place stator assembly over bushing, and press down to seat. Place stator connector in position. Tab should fit in notch of base and fastening eyelets should align with screw holes. Position wires away from moving parts. Install and tighten stator screws.
2. On all models except 3.8L, install octane rod through distributor base hole. Place end of rod onto same post as original stator. Install and tighten octane rod screw. On 3.8L models, ensure thrust washers are positioned in proper locations. (Scheme 2) On all models, lubricate distributor shaft, just below armature, with light oil. DO NOT over lubricate.
3. Install shaft through base bushing. Place a 1/2" deep well socket over shaft, invert assembly and place in arbor press. Place distributor drive gear on shaft. Align marks made during removal.
4. Place a 5/8" deep well socket over shaft and gear. Press gear until holes align with holes in shaft. If holes do not line up, press gear off and try again. DO NOT try to align holes using a drift or roll pin. Insert new roll pin through gear and shaft.
5. If armature has been removed, install armature. Tighten armature screws. Check distributor for freedom of rotation. If armature contacts stator, replace distributor. On all except 3.8L models, clean back of TFI ignition module and distributor contact plate.
6. Apply Silicone Dielectric Compound (D7AZ-19A331-A) to back of module, and spread evenly. Invert distributor base so stator connector is in full view. Insert TFI module.
7. Ensure module pins are inserted into stator connector. Fully seat TFI ignition module into connector and against base. Install and tighten TFI module screws. (Scheme 3)

Scheme 2

Scheme 3

OXYGEN SENSOR

O2 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.

Note. Fuel pressure must be released before performing work on fuel injection components.

1.8L & 2.2L

On non-turbo models, start engine. Disconnect vane airflow meter connector. On turbo models, remove fuel pump relay. Fuel pump relay is located behind left side of instrument panel, near steering column. Start engine, and operate until it stalls. Turn ignition off. Reconnect vane airflow meter connector or fuel pump relay.

ALL OTHER MODELS

Remove fuel tank cap. Using Fuel Pressure Gauge (T80L-9974-B), release pressure from system at pressure relief valve (Schrader valve), located on fuel injection manifold rail.

ALTERNATE METHOD (ALL MODELS)

Disconnect electrical connector to inertia switch located on left side of luggage compartment. Remove fuel cap to release fuel tank pressure. Crank engine 15 seconds to reduce system pressure.

REMOVAL (SPRING LOCK COUPLING)

1. Using Spring Lock Coupling Remover (D87L-9280-A for 3/8" or D87L-9280-B for 1/2"), remove 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 (SPRING LOCK COUPLING)

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 5)

Scheme 5

REMOVAL (HAIRPIN CLIP COUPLING)

Remove hairpin clip from fitting. 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.

INSTALLATION (HAIRPIN CLIP COUPLING)

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.

1. Disconnect negative battery cable. Disconnect air duct from throttle body. Remove accelerator cables and bracket. Disconnect all electrical connectors and vacuum lines from throttle body and intake plenum.
2. Mark and disconnect air by-pass and idle speed control hoses from intake plenum. Remove upper retaining bolts from intake plenum. Raise vehicle. Remove lower retaining bolts from intake plenum. Lower vehicle. Remove intake plenum and throttle body as an assembly.

Clean gasket surface. Install new gasket, and position intake plenum onto intake manifold. Install intake plenum bolts and nuts, and tighten to 14-19 ft. lbs. (19-25 N.m). To complete installation, reverse removal procedure. Refill cooling system.

1. Relieve fuel pressure. Disconnect negative battery cable. Drain coolant. Remove air cleaner assembly. Remove accelerator cables from throttle body and intake plenum.
2. Mark and remove all vacuum hoses from throttle body and intake plenum. Disconnect all electrical connections at throttle body and intake plenum. Remove engine lifting bracket mounting bolts from throttle body and engine block.
3. Remove coolant line/EGR hose retaining bracket from throttle body. Remove intake plenum retaining nuts and bolts. Remove intake plenum and throttle body as an assembly.

Clean gasket surface. Install new gasket, and position intake plenum onto intake manifold. Install intake plenum bolts and nuts, and tighten to 14-19 ft. lbs. (19-25 N.m). To complete installation, reverse removal procedure. Refill cooling system.

1. Disconnect air cleaner outlet tube from air intake throttle body. Disconnect throttle position sensor and air by-pass valve from wire harness. Mark and disconnect vacuum lines from intake plenum. Disconnect EGR tube at manifold connection.
2. Remove accelerator cables and speed control cable (if equipped). Remove top bolt from manifold upper support bracket. Remove fuel supply manifold shield. Remove 5 retaining bolts from intake plenum. Remove intake plenum and throttle body as an assembly.

Clean all gasket surfaces. Install new gasket on intake manifold. Mount intake plenum to intake manifold. Install manifold bolts, and tighten to 15-22 ft. lbs. (20-30 N.m). Reconnect EGR tube. Tighten to 31-45 ft. lbs. (41-56 N.m). To complete installation, reverse removal procedure.

1. Remove intake air boot from throttle body and mass airflow sensor. Disconnect throttle cable. Disconnect electrical connectors from TPS, air by-pass valve, vacuum switching valve and DIS module.
2. Disconnect coolant by-pass lines. Disconnect and mark all vacuum lines from intake plenum and throttle body. Disconnect EGR pipe from EGR valve.
3. Remove 8 bolts from intake plenum support brackets, and remove brackets. Remove bolt retaining coolant hose bracket. Remove 12 intake plenum bolts. Remove intake plenum with throttle body attached.

Clean all mounting surfaces. Position new gaskets and intake plenum assembly. Install retaining bolts, and tighten to 11-17 ft. lbs. (15-23 N.m). To complete installation, reverse removal procedure.

1. Disconnect wiring connector from air by-pass valve, TPS and EGR position sensor. Disconnect throttle and transmission linkages from throttle body. Remove cable bracket with cables attached, and position aside.
2. Identify and disconnect all vacuum lines to throttle body, intake plenum and intake manifold. Disconnect PCV system from fitting at rear of intake plenum. Remove EGR valve and EGR transducer.
3. Remove nut retaining alternator bracket to intake plenum. Remove 2 bolts retaining alternator bracket to water pump and alternator. Remove bolts holding intake plenum to intake manifold. Remove intake plenum and throttle body as an assembly.

Ensure mounting faces are clean. Position new gasket, and install intake plenum with throttle body onto intake manifold. Install bolts, and tighten to specifications. See INTAKE PLENUM TORQUE SPECIFICATIONS. On 3.8L Sable and Taurus models, tighten bolts in sequence. (Scheme 6) To complete installation, reverse removal procedure.

INTAKE PLENUM TORQUE SPECIFICATIONS

Scheme 6

THROTTLE BODY TORQUE SPECIFICATIONS

Scheme 7

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Remove fuel supply and return lines. See FUEL LINE CONNECTOR. Remove negative battery cable. Remove wiring harness from injectors.
2. Remove fuel rail retaining bolts. Carefully disengage injectors from fuel rail. On 1.8L & 1.9L, disconnect vacuum line from fuel pressure regulator. On all models, remove fuel rail assembly.

When installing fuel rail assembly, use new "O" rings. Push fuel rail down to ensure all injector "O" rings are fully seated in fuel rail cups and intake manifold. Install fuel rail retaining bolts. Tighten to specifications. To complete installation, reverse removal procedure.

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Remove negative battery cable. Remove intake plenum. See INTAKE PLENUM & THROTTLE BODY.
2. Remove electrical connectors from fuel injectors and engine coolant temperature switch (A/T only). Carefully bend wire harness retainer brackets away from intake manifold.
3. Remove fuel line from pulsation damper. See FUEL LINE CONNECTOR. Remove fuel return line bracket from intake manifold. Remove fuel return line.
4. Remove fuel rail attaching bolts, spacers and insulators. Remove fuel rail with injectors, pressure regulator and pulsation damper attached.

Position grommets and new "O" rings onto fuel injectors. Lightly lubricate "O" rings with engine oil. To complete installation, reverse removal procedure. Ensure injectors are properly seated.

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Remove fuel supply and return lines. See FUEL LINE CONNECTOR. Remove negative battery cable. Remove wiring harness from injectors.
2. Remove intake plenum. See INTAKE PLENUM & THROTTLE BODY. Remove injector retaining bolts. Carefully disengage fuel rail from injectors. Disconnect vacuum line from fuel pressure regulator. Remove fuel rail assembly.

When installing fuel rail assembly, use new "O" rings. Push fuel rail down to ensure all injector "O" rings are fully seated in fuel rail cups and intake manifold. Install fuel rail retaining bolts. Tighten to specifications. To complete installation, reverse removal procedure.

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Remove negative battery cable.
2. Remove intake plenum. See INTAKE PLENUM & THROTTLE BODY. Remove intercooler and intercooler tubes. See INTERCOOLER and INTERCOOLER INLET & OUTLET TUBES.
3. Remove cowl vent screens. Disconnect electrical connections and vacuum lines from intake elbow. Loosen clamp at air by-pass valve inlet hose. Remove 3 elbow-to-manifold retaining bolts.
4. Remove intake elbow. Remove fuel supply and return lines at fuel rail assembly. See FUEL LINE CONNECTOR. Remove wiring harness from fuel injectors. Remove fuel rail.

1. When installing fuel rail assembly, use new "O" rings. Push fuel rail down to ensure all injector "O" rings are fully seated in fuel rail cups and intake manifold.
2. Install fuel rail retaining bolts. Tighten to specifications. To complete installation, reverse removal procedure. When installing intake elbow, align paint stripe on hose with rib on elbow assembly.

FUEL RAIL BOLTS TORQUE SPECIFICATIONS

Removal & Installation

Injectors may be removed after fuel rail has been removed from intake manifold. See FUEL RAILS. Install new "O" rings on injectors. Inspect injector "plastic hat" (covering the injector pintle) and washer for deterioration. Replace as necessary.

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 3 Allen retaining screws from regulator housing. Remove pressure regulator assembly, gasket and "O" ring.
3. Make sure gasket 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.

1. Disconnect TPS from wiring harness. Mark throttle body and TPS for reassembly reference. Remove mounting screws and TPS. Slide rotary tangs of TPS into position over throttle shaft blade with wires pointing down. Rotate TPS clockwise to installed position.
2. Failure to install TPS in this manner may result in excessive idle speeds. Align marks on throttle body and TPS. Secure TPS to throttle assembly with retaining screws. Reconnect wiring.

Disconnect inlet and outlet tubes at intercooler. (Scheme 8) Slightly loosen inlet tube at alternator/power steering pump bracket. Remove intercooler retaining nuts and washers. Pull downward on intercooler to disengage from retaining clips. Remove intercooler.

1. Install Teflon tape to circumference of seat surfaces of intercooler inlet and outlet tubes. Keep tape close to inner diameter, and overlap ends 1/4".
2. Install intercooler in retaining clips. Install retaining nuts and washers. Ensure air boot fits on intercooler and no gaps exist. Install inlet and outlet tubes on intercooler.
3. Tighten inlet and outlet tube-to-intercooler nuts to 15-22 ft. lbs. (20-30 N.m). Ensure clamping connectors on inlet and outlet tubes at intercooler are parallel to intercooler surface. Tighten inlet tube-to-alternator/power steering bracket nut to 30-40 ft. lbs. (41-54 N.m). Operate engine and check for leaks.

Scheme 8

Removal (Inlet Tube)

1. Using Spanner (T89P-6634-A), disconnect inlet tube from supercharger. (Scheme 8) Disconnect outlet tube at intercooler. Remove inlet tube-to-intercooler nuts.
2. Remove nuts retaining inlet tube to alternator/power steering pump bracket. Remove stud from alternator/power steering pump bracket during inlet tube removal if necessary. Carefully remove inlet tube to avoid damaging sealing surfaces.

1. Ensure all sealing surfaces are clean. Install Teflon tape to circumference of sealing surfaces of intercooler inlet tube. Apply tape 1/8" from inner diameter, and overlap ends 1/4". Apply Anti-Seize Compound (ESE-M12A-4A) to sealing surface and threads of SC outlet adapter collar. CAUTION: DO NOT stretch Teflon tape during installation.
2. Install inlet tube. Install stud into alternator/power steering pump bracket. DO NOT damage sealing surfaces of inlet tube. Install push-on nut on stud enough to hold inlet tube. Ensure inlet tube is free to move for alignment of sealing surfaces.
3. Hand tighten supercharger outlet adapter collar on inlet tube. Install and slightly tighten inlet and outlet tube-to-intercooler nuts. Ensure tubes are free to move at sealing areas. Using adapter, tighten supercharger outlet adapter collar to 148 ft. lbs. (200 N.m). Wait at least 10 minutes, and retighten adapter collar to 148 ft. lbs. (200 N.m). CAUTION: Supercharger outlet adapter collar must be retightened after 10 minutes as Teflon tape will form to sealing surfaces.
4. Tighten inlet and outlet tube-to-intercooler nuts to 15-22 ft. lbs. (20-30 N.m). Ensure clamping connectors on inlet and outlet tubes at intercooler are parallel to intercooler surface. Tighten inlet tube-to-alternator/power steering bracket nut to 30-40 ft. lbs. (41-54 N.m). Start engine and check for leaks.

Removal (Outlet Tube)

1. Remove outlet tube-to-intake elbow assembly retaining nuts. Raise and support vehicle. Remove outlet tube-to-cylinder block front upper support bracket bolt.
2. Loosen (but DO NOT remove) support bracket at front of cylinder block. Bracket must remain close to cylinder block so bracket can pivot during installation of outlet tube.
3. Remove nut and push-on nut for outlet tube-to-alternator/power steering pump bracket. Remove inlet tube stud from alternator/power steering pump bracket. Remove power steering pump belt.
4. Disconnect spark plug wires at ignition coil. Remove power steering pump bracket brace-to-water pump nuts. Remove power steering pump bracket-to-cylinder head retaining bolts and stud nut.
5. Install a long bolt in top hole of power steering pump bracket to retain pump bracket in position. Remove power steering pump filler cap. Move power steering pump bracket outward on long bolt.
6. Remove outlet tube by moving tube underneath power steering pump bracket and up into engine compartment. DO NOT damage sealing surfaces of outlet tube during removal.

1. Install Teflon tape to circumference of sealing surfaces of outlet tube. Keep tape close to inner diameter, and overlap ends 1/4". DO NOT stretch tape during installation or a leak at sealing surface may develop.
2. Install outlet tube underneath power steering pump bracket assembly. Install power steering bracket and stud retaining nut. Tighten nut to 30-40 ft. lbs. (41-54 N.m). CAUTION: Carefully install outlet tube to avoid damaging sealing surfaces.
3. Remove bolt installed in step 5 during removal. Install power steering pump bracket-to-cylinder head bolts, and tighten to 30-40 ft. lbs. (41-54 N.m).
4. Install power steering pump bracket brace-to-water pump retaining studs. Tighten nuts to 15-22 ft. lbs. (20-30 N.m). Install outlet tube on lower stud on alternator/power steering pump bracket.
5. Install push-on nut to hold outlet tube on pump bracket. Ensure outlet tube is free to move for alignment of sealing surfaces. Install outlet tube clamping connector over intake elbow assembly studs. Install and tighten nuts to 15-22 ft. lbs. (20-30 N.m). Ensure clamping connectors on outlet tube-to-intake elbow are parallel to intake elbow surface.
6. Install nut on stud of alternator/power steering pump bracket. Tighten nut to 30-40 ft. lbs. (41-54 N.m). Install outlet tube-to-cylinder block support bracket. Tighten bolt to 30-40 ft. lbs. (41-54 N.m).
7. Tighten support bracket-to-front of cylinder block retaining nut to 15-22 ft. lbs. (20-30 N.m) and bolt to 52-70 ft. lbs. (71-95 N.m).

Note. Disassembly of supercharger unit may void warranty. Supercharger is serviced by replacement ONLY.

SUPERCHARGER 3.8L

Note. Supercharger cannot be overhauled. Supercharger is serviced by replacement ONLY.

1. Clean areas surrounding supercharger. Disconnect negative battery cable. Remove throttle body air inlet tubes. Remove cowl vent screens. Partially drain cooling system.
2. Remove right side spark plug wires at ignition coil. Remove all vacuum and electrical connectors from intake plenum and throttle body. Remove throttle linkage and bracket. Remove supercharger drive belt.
3. Disconnect speed control (if equipped). Remove supercharger drive belt. Remove intercooler inlet and outlet tubes. See «INTERCOOLER INLET & OUTLET TUBES»(/ford/escort/v-1990-1992/remont/removal-installation/#engine-controls-removeinstalloverhaul).
4. Remove 3 intake elbow retaining bolts. Remove 3 supercharger retaining bolts. Lift supercharger and intake assembly from vehicle as a unit. (Scheme 8) To install, reverse removal procedure.

TURBOCHARGER 2.2L

Note. Turbocharger cannot be overhauled. Turbocharger is serviced by replacement ONLY.

Before removing turbocharger, follow these precautions

1. Clean area surrounding turbocharger using a non-caustic cleaner.
2. After unit removal, cover all engine openings with clean cloth to prevent entry of foreign matter.
3. Ensure blades are not nicked or otherwise damaged. An imbalance condition could result and lead to severe damage.
4. If any internal engine component is replaced, change oil and filter, and flush turbocharger with clean oil.
5. Before installing turbocharger on engine, gently spin blades to ensure freedom of movement.

1. Disconnect negative battery cable. Drain cooling system. Disconnect turbocharger outlet hose. Remove heat shields from exhaust manifold and turbocharger assembly. Disconnect exhaust gas oxygen sensor electrical connector (if necessary).
2. Disconnect oil feed and return lines from turbocharger. (Scheme 9) Disconnect coolant inlet and outlet hoses from turbocharger. Remove EGR tube from exhaust manifold.
3. Disconnect air tube and electrical connector from boost control solenoid. Remove mounting bolt from turbocharger retaining bracket, located under turbocharger. Discharge A/C system pressure. Remove refrigerant line from A/C compressor. Remove exhaust gas oxygen sensor (if necessary).
4. Remove converter inlet pipe from turbocharger joint pipe. Remove exhaust manifold and turbocharger as an assembly. Separate exhaust manifold, turbocharger-to-converter inlet pipe, joint pipe and heat shield assembly from turbocharger.

Scheme 9

1. Fill oil cavity of turbocharger with oil. Install joint pipe and heat shield assembly onto turbocharger. Tighten mounting bolts to 27-46 ft. lbs. (37-63 N.m).
2. Install exhaust manifold onto turbocharger, and tighten mounting bolts to 20-29 ft. lbs. (27-39 N.m). To complete installation, reverse removal procedure. Add .85 oz. of engine oil to turbocharger before installing oil feed line. After installation, disconnect coil wire, and crank engine 20 seconds.
3. Connect coil wire. Start engine, and run at idle 30 seconds. Stop engine, disconnect negative battery cable and depress brake pedal for at least 5 seconds to cancel ECA trouble code. Reconnect negative battery cable.

Disconnect negative battery cable. Disconnect airflow meter electrical connector. Remove air duct from air filter cover. Remove air filter cover attaching bolts and cover. Remove vane airflow meter attaching nuts. On 2.2L models, VAF attaching nuts are located inside air cleaner cover. On all models, remove airflow meter. To install, reverse removal procedure.

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Drain fuel from tank. Raise vehicle on hoist. Remove exhaust pipe and shield. Remove fuel hoses and tubes. See FUEL LINE CONNECTOR.
2. Disconnect vapor crossover and filler hoses. Support fuel tank. Remove fuel tank strap bolts. Partially lower fuel tank. Disconnect fuel lines and electrical connector from fuel gauge sender. Remove fuel tank.
3. Remove any dirt around fuel pump retaining flange area. Using Fuel Tank Sender Wrench (D84P-9257-A), remove fuel pump locking ring. Remove fuel pump.

1. Clean fuel pump mounting flange, fuel tank mounting surface and seal ring groove. To hold new seal ring in place during installation, apply a light coating of Long Life Lubricant (C1AZ-19590-BA) on seal ring.
2. Install seal ring in fuel ring groove. Install fuel pump and sender assembly. DO NOT damage nylon filter. Ensure locating keys are in keyways and seal ring remains in place.
3. Tighten locking ring by rotating ring clockwise using Fuel Tank Sender Wrench (D84P-9257-A) until ring stops against stops. To complete installation, reverse removal procedure.

Relieve fuel pressure. Disconnect negative battery cable. Completely drain fuel tank by siphoning or pumping fuel out through one of the fuel filler hoses. Remove rear seat bottom cushion. Remove ground strap screw and three remaining fuel pump cover screws. Remove fuel pump cover. Disconnect fuel lines and electrical connector from fuel gauge sender. Remove any dirt around fuel pump retaining flange area. Using Fuel Tank Sender Wrench (D84P-9257-A), remove fuel pump locking ring. Remove fuel pump. Installation is reverse of removal.

Removal (Crown Victoria, Grand Marquis & Town Car)

1. Remove air cleaner outlet tube. Raise vehicle on hoist. Hold EGR valve tube to manifold connector with a wrench while disconnecting EGR valve to exhaust manifold tube. Use care not to damage EGR valve tube to manifold connector. Disconnect EGR valve to exhaust manifold tube from EGR valve and EGR valve tube to manifold connector. Lower vehicle.
2. Disconnect EGR pressure sensor hoses from EGR valve to exhaust manifold tube. Disconnect vacuum hose from EGR valve. Remove two EGR valve retaining bolts. Remove EGR valve, EGR valve gasket and EGR valve to exhaust manifold tube from vehicle.

1. Clean intake manifold sealing surface with a plastic-tipped scraper to remove any residual EGR valve gasket material. Position EGR valve to exhaust manifold tube into EGR valve and loosely connect EGR valve to exhaust manifold tube nut to EGR valve. Do not tighten EGR valve to exhaust manifold tube nut on EGR valve at this time.
2. Position EGR valve gasket, EGR valve and EGR valve to exhaust manifold tube into vehicle. Install two bolts retaining EGR valve to intake manifold. Tighten bolts to 15-22 ft. lbs. (20-30 N.m). Connect vacuum hose to EGR valve. Connect EGR pressure sensor hoses to EGR valve to exhaust manifold tube.
3. Raise vehicle. Connect EGR valve to exhaust manifold tube to EGR valve tube to manifold connector. Hold EGR valve tube to manifold connector with a wrench while tightening EGR valve to exhaust manifold tube nut. Tighten EGR valve to exhaust manifold tube nuts to 23-33 ft. lbs. (35-45 N.m). Lower vehicle. Install air cleaner outlet tube.

See also:
• INTAKE PLENUM TORQUE SPECIFICATIONS