Engine Controls - Remove/install/overhaul: Removal & Installation Ford Escort V facelift 2

Removal & Installation

1. CKP sensor is located on side front cover near crankshaft pulley. Disconnect negative battery cable. Remove serpentine drive belt. Raise and support vehicle. Disconnect sensor connectors.
2. Remove sensor bolt and sensor. To install, reverse removal procedure. Tighten sensor bolt to specification. See «TORQUE SPECIFICATIONS»(ref-24200-S12725882472001010400000) . Evacuate and recharge A/C system.

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

Removal (Spring Lock Coupling)

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-24200-S27295852052001010400000). 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

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 "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. Disconnect negative battery cable. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-24200-S27295852052001010400000) . Remove fuel rail.
2. Remove CMP sensor screws and sensor. To install, use new "O" rings on CMP sensor and tighten sensor screws to 40-61 ft. lbs. (5-7 N.m). To complete installation, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-24200-S12725882472001010400000) .

Removal

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-24200-S27295852052001010400000) . Disconnect negative battery cable. Depress 2 clips securing front of rear seat cushion, and remove seat cushion. Disconnect wiring harness connectors from fuel pump assembly.
2. Remove fuel pump access cover. Remove any dirt from around fuel pump flange area. Disconnect fuel inlet and return lines from fuel pump. Remove fuel pump lock retainer ring, and remove fuel pump assembly.

Clean fuel pump mounting flange, fuel tank mounting surface and seal ring groove. Install seal ring in fuel ring groove. Install fuel pump assembly. Install and tighten fuel pump lock retainer ring. To complete installation, reverse removal procedure. Fill fuel tank and check for leaks.

1. Disconnect the battery ground cable.
2. Relieve the fuel pressure; refer to
3. Loosen the fuel filter bracket clamp bolt.
4. Remove the fuel filter. Remove the fuel line clips and disconnect the fuel lines. Remove the fuel filter from the bracket.

Scheme 4

Note. When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven.

Note. Install using new fuel line clips if necessary.

To install, reverse the removal procedure.

Scheme 5

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-24200-S27295852052001010400000) . Disconnect negative battery cable. Disconnect CKP and CMP harness connectors. Disconnect 2 main harness connectors located above right wheel well. Disconnect wiring harness sheathe from fuel rail.
2. Disconnect vacuum line from fuel pressure regulator. Disconnect fuel supply and return lines. See «FUEL LINE CONNECTOR»(ref-24200-S11153721142001010400000) . Remove wiring harness from injectors. Remove fuel rail mounting bolts. Carefully disengage fuel rail from fuel injectors. Remove fuel rail.

1. If removing fuel pressure regulator while fuel rail assembly is still installed on engine, release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-24200-S27295852052001010400000) .
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.

Release fuel system pressure. See procedures under FUEL SYSTEM PRESSURE RELEASE . Remove fuel rail from intake manifold. See FUEL RAILS . Remove fuel injectors from fuel rail by rocking injectors while pulling injector from fuel rail. To install, reverse removal procedure. Lubricate new "O" rings with clean engine oil. Install new "O" rings on injectors. Inspect injector end cap (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 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.