Ford Escort, EXP, Mercury Lynx, LN7 Repair & Service Manual 1981-1990

1988-1990 1.9L HO ENGINES | LOWER INTAKE MANIFOLD ASSEMBLY (See Figure 19)

1. Disconnect the negative battery cable.



2. Properly relieve the fuel system pressure.



3. Disconnect the engine air cleaner outlet tube from the air intake throttle body.



4. Tag and unplug the Throttle Position (TP) sensor electrical connection.



5. Disconnect and remove the accelerator and speed control cables, if equipped, from the accelerator mounting bracket and throttle lever.



6. Unfasten the top manifold vacuum fitting connections by disconnecting the rear vacuum line to the dash panel vacuum tree and the vacuum line at the intake manifold tee.



7. Disconnect the PCV system by disconnecting the hoses from the PCV valve at the intake manifold connection.



8. Disconnect the EGR vacuum line at the EGR valve. Disconnect the EGR tube from the upper intake manifold by supporting the connector while loosening the compression nut.



9. Disconnect the upper support manifold bracket by removing the top bolt only. Leave the bottom bolts attached.



10. If necessary, remove the upper intake manifold.



11. Disconnect the electrical connectors at the main engine harness, near the No. 1 runner, and at the ECT sensor located in the heater supply tube.



12. Remove the fuel supply and return lines.



13. Remove the six manifold mounting nuts.



14. Disconnect the lower support manifold bracket by removing the top bolt only. Leave the bottom bolts attached.

1.6L AND 1.9L MFI ENGINES (See Figure 26)

1. Properly relieve the fuel system pressure.



2. Raise the vehicle and support it with safety stands.



3. Unfasten bolt A (refer to the accompanying illustration) until the assembly can be removed from its mounting bracket.



4. Remove the parking brake cable from the clip on the pump.



5. Unplug the electrical connector and disengage the pump outlet fitting at point C (refer to the accompanying illustration).



6. Disconnect the pump outlet fitting at point B (refer to the accompanying illustration).



7. Remove the fuel pump.


CAUTION: Drain the fuel tank or raise the end of the fuel line above the fuel level to avoid siphoning action.

TO INSTALL


8. Attach the fuel pump to the fuel tank support bracket. Tighten the mounting bolt to 19.5-30 inch lbs. (2.2-3.4 Nm).



9. Attach the parking brake cable to its retaining clip on the pump.



10. Attach the fuel lines to the pump.



11. Lower the vehicle.



12. Attach a fuel pressure gauge to the fitting on the fuel rail.



13. Turn the ignition key ON and OFF in 2-second intervals until the fuel pressure reads at least 35 psi (241 kPa).



14. Check for leaks at the pump and the fuel lines.



15. Remove the gauge, start the engine and recheck for leaks.

• Tune-up and routine maintenance
• Engine and overhaul procedures
• Cooling, heating and air-conditioning systems
• Fuel and exhaust systems
• Engine electrical systems
• Emissions control systems
• Transmission
• Brakes
• Suspension and steering systems
• Body
• Chassis electrical system
• Wiring diagrams