Section 03-04A: Fuel Charging and Controls—2.3L
1993 Mustang Workshop Manual
REMOVAL AND INSTALLATION

Fuel Supply Manifold Assembly

Tools Required:

 

Removal

NOTE: The cap on the relief valve must be removed.

  1. Remove fuel tank cap and release pressure from the fuel system by opening the pressure relief valve in the upper RH corner of the engine compartment using MFI Pressure Gauge T80L-9974-B.
  1. Remove the upper intake manifold as outlined.
  1. Remove injector electrical connectors.
  1. Remove spring lock coupling retainer clips from fuel inlet and return fittings.
  1. Disconnect the push-connect fitting at the fuel supply manifold and fuel return lines.



  1. Remove two fuel supply manifold retaining bolts.
  1. Carefully disengage manifold and fuel injectors from engine and remove manifold and injectors.

    NOTE: The injectors may be removed from the manifold at this point, following instructions outlined under Fuel Injector Removal.

 

Installation

 CAUTION: Never use silicone grease. It will clog the injectors. Make sure the injector caps are clean and free of contamination.

  1. Lubricate new O-rings with clean engine oil XO-10W30-QSP (ESE-M2C153-E) or equivalent.
  1. Install the fuel injector supply manifold and injectors into the intake manifold.
  1. Push the fuel rail down to ensure all fuel injector O-rings are fully seated in the fuel rail cups and intake manifold.
  1. Secure the fuel manifold assembly using two retaining bolts, while holding the fuel rail down. Tighten to 20-30 Nm (15-22 lb-ft).
  1. Connect fuel supply and return lines to fuel supply manifold.
  1. Reinstall spring lock coupling retainer clips on fuel inlet and return fittings.
  1. After the fuel rail assembly has been installed and before the fuel injector wire connectors have been connected, turn the key to the ON position. This will cause the fuel pump to run for two to three seconds and pressurize the fuel system.
  1. Using a clean paper towel, check for leaks where the fuel injector is installed into the fuel rail.
  1. Install the upper intake manifold as outlined.
  1. Install the cap on the relief valve if removed.
  1. Connect the fuel injector wire connectors. Start the engine and let it idle for two minutes.
  1. Turn the engine off and check for fuel leaks where the fuel injector is installed in the fuel rail, intake manifold or cylinder head.