Description and operation principle (1.6L Zetec-SE/1.4L) Fuel supply and controls Pos. Spare Part No Name 1 Fuel pressure control 2 fuel manifold 3 Injector clamp 4 O-rings of circular section of the nozzle 5 Fuel burner The...
Diagnostics and checks (1.6L Zetec-SE/1.4L) Inspection and verification 1. Check the legitimacy of the customer's complaint by activating the system. 2. Visually inspect for obvious signs of mechanical and...
Throttle body (1.6L Zetec-SE/1.4L) Withdrawal CAUTION: Do not attempt to clean the throttle body. The bore and throttle valve have a special coating applied at the factory that must not be removed. 1....
Fuel injectors (1.6L Zetec-SE/1.4L) Withdrawal WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations, there are always...
Fuel System Wiring Harness (1.6L Zetec-SE/1.4L) Special tool Pliers for spark plug connectors 303-622 (21-226) Withdrawal 1. Relieve pressure in the fuel supply system. See Section 303-00 for more information. 2....
Fuel supply manifold (1.6L Zetec-SE/1.4L) Withdrawal WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations, there are always...
Fuel pressure regulator (1.6L Zetec-SE/1.4L) Withdrawal WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations, there are always...
Description and function (1.8L/2.0L/1.6L Zetec-E) Fuel supply and controls Pos. Spare Part No Name 1 Fuel pressure control 2 fuel manifold 3 Injector clamp 4 O-rings of circular section of the nozzle 5 Fuel burner The...
Diagnostics and Checks (1.8L/2.0L/1.6L Zetec-E) Inspection and verification 1. Check the customer's complaint. 2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Table...
Throttle body (1.8L/2.0L/1.6L Zetec-E) Withdrawal CAUTION: Do not attempt to clean the throttle body. The bore and butterfly valve have a special coating applied at the factory that must not be removed. 1....
Fuel injectors (1.8L/2.0L/1.6L Zetec-E) Withdrawal WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations, there are always...
Fuel System Wiring Harness (1.8L/2.0L/1.6L Zetec-E) Withdrawal 1. Disconnect a wire of weight from the accumulator. See Section 414-01 for more information. 2. Disconnect the air filter outlet pipe. 3. Disconnect the...
Fuel Supply Manifold (1.8L/2.0L/1.6L Zetec-E) Withdrawal WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations, there are always...
Fuel pressure regulator (1.8L/2.0L/1.6L Zetec-E) Withdrawal WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations, there are always...
Diagnostics and checks (1.8 l diesel) Inspection and verification WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related components. In such...
Fuel injectors (1.8 l diesel) Withdrawal All cars 1. WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations,...
High pressure fuel pump (1.8L diesel) Special tool Hand vacuum/pressure pump 23-036A (416-D001) High pressure fuel pump pulley puller 310-095 (23-067) Withdrawal All cars 1. WARNING: Do not smoke or walk...
Specifications (turbocharger) Torque Specifications Name Nm pound foot lb-in Engine roll stop bolt 48 35 - Oil supply nipple connection - vehicles with a 75 hp diesel engine. or 90 hp 10 - 89 Oil...
Description and principle of operation (turbocharger) Vehicles with 70 hp diesel engine or 90 hp Pos. Spare Part No Name 1 - Turbocharger/exhaust manifold The turbocharger consists of two elements: a turbine and a...
Diagnostics and checks (turbocharger) Special tool Boost pressure gauge 310 - 020 (23 - 021) Manual vacuum/pressure pump 416 - D001 (23 - 036A) How it works - Vehicles with a 75 hp diesel engine. or 90 hp...
Inspection and testing (turbocharger) NOTE: It is normal for a small amount of gases from the combustion chamber to enter the crankcase. This gas is blown into the air intake system thanks to the forced...
Pinpoint tests (turbocharger) PINPOINT TEST A: NOISY TURBO/BLACK OR BLUE SMOKE STATES DETAILS/RESULTS/ACTIONS A1: INSPECTION OF TURBO ROTOR BLADES FOR DAMAGE 1 Disconnect the air filter outlet pipe...
Turbocharger 1.8L Diesel (75 PS/90 PS) Withdrawal All cars 1. Disconnect a wire of weight from the accumulator. See Section 414-01 for more information. 2. Remove the air filter. See Section 303-12 for more...
Turbocharger 1.8L fuel injected diesel Withdrawal 1. Disconnect a wire of weight from the accumulator. See Section 414-01 for more information. 2. Remove the air filter. See Section 303-12 for more...
Specification (fuel injected diesel) Torque specification Name Nm Pound-foot Pound inch Bolt of fastening of a clip of a fuel nozzle 38 28 - Fuel rail mounting bolts 28 21 - Lower bolts of fastening of a...
Description and function (fuel injected diesel) Fuel supply and controls Pos. Spare Part No Name 1 Fuel burner 2 Bolt of fastening of a fuel nozzle 3 fuel injector clamp 4 High pressure fuel supply lines (from the...
Diagnostics and Checks (Diesel Fuel Injection) Inspection and verification WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations,...
Fuel injectors (fuel injected diesel) Special tool World Diagnostic System (WDS) 418-F224 General equipment: Pneumatic vacuum gun. Name Specification Lubricant for the nipple connection of the high pressure...
Fuel supply manifold (fuel injected diesel) Special tool World Diagnostic System (WDS) 418-F224 General equipment: Pneumatic vacuum gun. Name Specification Lubricant for the nipple connection of the TBD high...
Fuel Pump (Diesel Fuel Injection) Special tool World Diagnostic System (WDS) 418-F224 Hand vacuum/pressure pump 23-036A (416-D001) General equipment: Vacuum cleaner for engine. Name Specification...
Fuel return line with venturi nozzle General equipment: Pneumatic vacuum gun. Withdrawal All cars WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel...
Specifications (Duratec ST 2.0L) Torque specification Name Nm lb-ft lb-in throttle body 7 - 62 Fuel manifold bolts 10 - 89 Spark plug cover bolts 8 - 71
Throttle Body (Duratec ST 2.0L) Withdrawal CAUTION: Do not attempt to clean the throttle body. The bore and throttle valve have a special coating applied at the factory that must not be removed. 1....
Fuel system wiring harness (Duratec ST 2.0L) Withdrawal 1. Disconnect a wire of weight from the accumulator. See Section 414-01 for more information. 2. Remove the ignition coil cover. 1. Disconnect the clips. 2....
Fuel supply manifold (Duratec ST 2.0 l) Withdrawal WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations, there are always...
Diagnostics and checks (1.6L Duratec) Inspection and verification 1. Check the customer's complaint. 2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Table...
Throttle body (1.6L Duratec) Withdrawal CAUTION: Do not attempt to clean the throttle body. The bore and butterfly valve have a special coating applied at the factory that should not be removed. 1....
Fuel System Wiring Harness (1.6L Duratec) Withdrawal 1. Disconnect the fuel injection harness connector. 2. Disconnect the plug connector of the camshaft position sensor (SMR). 3. Disconnect the fuel supply...
Fuel supply manifold (1.6L Duratec) Withdrawal 1. Relieve fuel pressure. Refer to Section 310-00 for more information. 2. Disconnect the positive crankcase ventilation hoses (PCV) from the intake manifold...
Diagnostics and checks of the fuel supply system Special tool Manual vacuum/pressure pump 416-D001 (23-036A) Inspection and verification 1. Check the customer's complaint. 2. Perform a visual check for obvious signs of...
Pinpoint tests of the fuel delivery system PINPOINT TEST A: AIR INTRODUCTION TO FUEL LINES - VEHICLES WITH 75 HP DIESEL ENGINE OR 90 HP STATES DETAILS/RESULTS/ACTIONS WARNING: Do not smoke or walk around with a...
Relieving pressure in the fuel supply system 1. WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related components. In such situations, there are always...
Quick coupler — disconnection and connection Disconnection WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. There are always highly flammable...
Emptying the fuel tank Drain WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related components. In such situations, there are always...
Couplings with spring lock — disconnection and connection Special tool Spring Lock Disconnect Tool (3/8», yellow color) 310-D004 (23-039) Spring Lock Disconnect Tool (1/2», green color) 310-D005 (23-040) Spring Lock Disconnect...
Fuel tank and fuel lines Torque specification Name Nm Pound-foot Pound inch Bolt of a collar of fastening of a fuel tank 25 18 - Exhaust flange bolts 48 35 - Filler pipe bolts 9 - 80 Fuel tank...
Fuel tank — removal and installation Withdrawal WARNING: Do not smoke or allow lit cigarettes or any open flame to be present when working on or near any fuel-containing elements. In such situations, there...
Fuel pump module — removal and installation Special tool Key for fuel tank sensor 310-069 (23-055) Withdrawal 1. Remove the fuel tank. For more information, refer to the chapter Fuel tank available in this...
Fuel tank filler pipe — removal and installation Withdrawal 1. WARNING: Do not smoke or allow lit cigarettes or any open flame to be present when working on or near any fuel-containing elements. In such situations,...
Fuel filter — removal and installation Withdrawal 1. WARNING: Do not smoke or allow lit cigarettes or any open flame to be present when working on or near any fuel-containing elements. In such situations,...
Fuel filter (1.8 l diesel) — removal and installation Withdrawal 1. WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations, highly...
Inertial Fuel Cutoff Switch (IFS) Withdrawal 1. Remove the panel of finishing of an aperture of the right forward door. 2. Disconnect the electrical connector. 3. Remove the fuel inertia switch....
Acceleration control (accelerator) The acceleration control system consists of an accelerator pedal and an accelerator cable. The driver, pressing the accelerator pedal, installed in the passenger...
Accelerator pedal — removal and installation Withdrawal 1. Remove the footwell trim panel. 2. Disconnect the accelerator cable from the pedal. 3. Remove the pedal and bracket. Installation 1. Replace the elements...
Speed control Torque specification Name Nm Pound-foot Pound inch Speed Control Actuator Nuts 6 - 53 Speed Control Switch Bolts 5 - 44 Pos. Spare Part No Name 1 - Speed Control Drive...
Speed control diagnostics and checks Inspection and verification 1. Check the validity of the customer's complaint by activating the system. 2. Visually inspect for obvious signs of mechanical and...
Pinpoint speed control tests PINPOINT TEST A: SPEED CONTROL NOT WORKING STATES DETAILS/RESULTS/ACTIONS A1: BEEP FUNCTION TEST 1 Press the horn switches. • Does the alarm sound? → Yes Go to A2 → No...
Speed Control Deactivator Switch Adjustment 1. Adjust the switch. 1. Extend the switch plunger to its full stroke. 2. Fully depress the pedal. 3. Set the switch. 4. Slowly release the pedal.
Speed control cable Withdrawal 1. Remove the air filter outlet pipe. 2. Disconnect the speed control cable from the throttle body. 3. Disconnect the speed control cable from the bracket. 4....
Speed Control Cable (Duratec ST 2.0 L) Withdrawal 1. Release the speed control cable from the clamp. 2. Disconnect the speed control actuator cable cover. 3. Disconnect the speed control cable from the speed...
Speed control system switch Withdrawal 1. Remove the driver's airbag module. See Section 501-20B for more information. 2. Disconnect the speed control switch electrical connector. 3. Remove the...