Ford Fusion Manuals

Ford Fusion: Fuel Charging and Controls - 1.5L EcoBoost (118kW/160PS) – I4 / High-Pressure Fuel Pump. Removal and Installation

Materials

Name Specification
Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil
XO-5W20-Q1SP
WSS-M2C945-B1
 

Removal

NOTICE: Do not loosen any fittings or plugs on the high-pressure fuel pump.

  1. Release the fuel system pressure.
    Refer to: Fuel System Pressure Release (310-00A Fuel System - General Information - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
  1. Disconnect the battery.
    Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

    1. Disconnect the high-pressure fuel pump fuel feed tube spring lock coupling.
      Refer to: Spring Lock Couplings (310-00A Fuel System - General Information - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
    1. Disconnect the high-pressure fuel pump electrical connector.
Ford Fusion. High-Pressure Fuel Pump. Removal and Installation
  1. NOTICE: To release the fuel pressure in the high pressure fuel tube, wrap the high-pressure fuel pump flare nut with a shop towel to absorb any residual fuel pressure during the loosening of high-pressure fuel pump flare nut.

    Disconnect the high-pressure fuel tube flare nuts. Remove and discard the high-pressure fuel tube.
Ford Fusion. High-Pressure Fuel Pump. Removal and Installation
  1. NOTE: Alternately loosen the high-pressure fuel pump bolts one complete revolution at a time.

    Remove the high-pressure fuel pump bolts and then remove the high-pressure fuel pump.
Ford Fusion. High-Pressure Fuel Pump. Removal and Installation
  1. Remove the high-pressure fuel pump drive tappet.
Ford Fusion. High-Pressure Fuel Pump. Removal and Installation
  1. Inspect the high-pressure fuel pump tappet. If any flat spots or scoring are found, especially in the indicated areas, then inspect the high-pressure fuel pump and the high-pressure fuel pump tappet drive lobe. Install new components as necessary.
Ford Fusion. High-Pressure Fuel Pump. Removal and Installation

Installation

  1. The cam lobe for the high-pressure fuel pump must be at BDC for the high-pressure fuel pump installation.
Ford Fusion. High-Pressure Fuel Pump. Removal and Installation
  1. NOTICE: Only rotate the crankshaft Clockwise (CW) or damage to the engine may occur.

    Using the crankshaft pulley bolt, turn the crankshaft until the high-pressure fuel pump cam lobe is at BDC.
Ford Fusion. High-Pressure Fuel Pump. Removal and Installation
  1. Apply clean engine oil to the high-pressure fuel pump drive unit bore and the drive lobe and the roller tappet. Install the high-pressure fuel pump tappet.
    Material: Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)
Ford Fusion. High-Pressure Fuel Pump. Removal and Installation
  1. Install a new high-pressure fuel pump O-ring seal. Lubricate with clean engine oil.
    Material: Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)
Ford Fusion. High-Pressure Fuel Pump. Removal and Installation
  1. NOTE: Make sure that 2 new high-pressure fuel pump mounting bolts are installed.

    Install the high-pressure fuel pump and loosely install the high-pressure fuel pump bolts, alternately tighten each bolt 90° at a time in turn until the torque is achieved.
    Torque: 80 lb.in (9 Nm)
Ford Fusion. High-Pressure Fuel Pump. Removal and Installation
  1. NOTE: Only tighten the 2 high pressure fuel tube flare nuts finger tight at this stage.

    NOTE: Make sure that a new high pressure fuel tube is installed.

    NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas.

    Tighten the high-pressure fuel tube flare nuts in the following 3 stages.
    Torque:
      Stage 1:  15 lb.ft (21 Nm)
      Stage 2:  Wait 5min
      Stage 3:  15 lb.ft (21 Nm)
Ford Fusion. High-Pressure Fuel Pump. Removal and Installation

    1. Connect the high-pressure fuel pump fuel feed tube spring lock coupling.
      Refer to: Spring Lock Couplings (310-00A Fuel System - General Information - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
    1. Connect the high-pressure fuel pump electrical connector.
Ford Fusion. High-Pressure Fuel Pump. Removal and Installation
  1. Connect the battery.
    Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Pressurize the fuel system.
    Refer to: Fuel System Pressure Release (310-00A Fuel System - General Information - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).

    Fuel Rail. Removal and Installation

    Special Tool(s) / General Equipment 303-1567Sizer, Teflon SealTKIT-2010C-FLM 307-005 (T59L-100-B) Slide Hammer 310-205Fuel Injector Brush 310-206Remover, Fuel InjectorTKIT-2009A-FLM 310-206-01Adapter for 310-206 310-207Installer, Fuel Injector Seal AssemblyTKIT-2009A-FLM Removal Release the fuel system pressure...

    High-Pressure Fuel Pump Drive Unit. Removal and Installation

    Materials Name Specification Flange SealantCU7Z-19B508-A WSS-M2G348-A11  Motorcraft® Metal Surface Prep WipesZC-31-B -  Removal Remove the high-pressure fuel pump...

    Other information:

    Ford Fusion 2013–2020 Service Manual: Fuel Pump Driver Module (FPDM). Removal and Installation


    Removal NOTE: The fuel pump driver module is located behind the left C-pillar lower trim panel. Remove the left C-pillar lower trim panel. Refer to: C-Pillar Lower Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation)...

    Ford Fusion 2013–2020 Service Manual: Overhead Console. Removal and Installation


    Removal NOTE: Removal steps in this procedure may contain installation details. NOTE: Consoles look different depending on option level. Insert trim tool in location(s) shown. Rotate the tool 90 degrees to release the overhead console rear retainers...

    Categories

    Manual Climate Control

    Ford Fusion. Manual Climate Control

    Note: Depending on your vehicle option package, the controls may look different from what you see here.

    read more

    Copyright © 2022 www.fofusion2.com