Fuel Injection Supply Manifold

FUEL INJECTION SUPPLY MANIFOLD

Removal and Installation

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.

WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions may result in personal injury.

1. Relieve the fuel system pressure. Refer to FUEL SYSTEM PRESSURE RELEASE - 2.0L ZETEC.
2. Disconnect the battery ground cable. Refer to BATTERY DISCONNECT.
3. Remove the air cleaner outlet pipe. Refer to AIR CLEANER OUTLET PIPE - 2.0L ZETEC.




4. Using the Special tool, disconnect the fuel line.




5. Disconnect the accelerator cable and, if equipped, the cruise control actuator cable.




6. Disconnect the fuel pulse damper vacuum hose.




7. Disconnect the fuel injector electrical connectors.




8. Remove the bolts and remove the fuel supply manifold.




9. Inspect the O-ring seals. Discard if damaged.

CAUTION: Use O-ring seals made of fuel-resistant material. Use of incorrect O-ring seals may result in fuel leakage.

CAUTION: Never use silicone grease. Silicon grease may clog fuel injectors.

NOTE: Lubricate the O-ring seals with clean SAE 5W-30 motor oil to aid installation.

10. To install, reverse the removal procedure.

FUEL INJECTION SUPPLY MANIFOLD

Removal and Installation

WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions may result in personal injury.

1. Remove the upper intake manifold. Refer to UPPER INTAKE MANIFOLD.
2. Disconnect the fuel line. Refer to SPRING LOCK COUPLINGS.






NOTE: One connector is shown, the other five connectors are similar.

3. Disconnect the six fuel injector electrical connectors and release the wiring harness locators from the fuel injection supply manifold.

4. Remove the fuel injection supply manifold.
1. Remove the vacuum hose.




2. Remove the bolts and the manifold,

NOTE: Lubricate the fuel injector O-ring seals with clean engine oil to aid installation.

5. To install, reverse the removal procedure.