Vortech Ford SVT Contour/Mercury 2.5L V6 Cougar User Manual

Page 16

P/N: 4FS020-010
©2002 Vortech Engineering, Inc.
All Rights Reserved, Intl. Copr. Secured
11JAN02 V2.0

(Cougar (4FS V2.0))

FUEL INJECTOR REPLACEMENT, (1999-2000 “returnless fuel” vehicles only)

A. Disconnect the EGR tube from the EGR valve at

the rear of the upper intake manifold. Remove all
bolts securing the upper manifold to the lower
manifold. Unplug the electrical connector from
the fuel pressure sensor. The upper manifold
should move up enough to access all fuel injec-
tors.

B. Disconnect the six fuel injector wiring clips and

retainers from the fuel injectors. Release any
residual fuel pressure from the rail by opening
the schrader valve.

C. Remove the plastic from around the injector

wires. Remove the bolts holding down the factory
fuel rail. Lift up on the rail evenly and remove all
six injectors.

D. Using a small amount of clean motor oil, lightly

lubricate the O-rings on both ends of the Vortech
supplied fuel injectors.

Install the new injectors into the fuel rail with the

terminals facing outward.

Carefully lower the fuel rail/injector assembly

down onto the intake manifold. Check to see that
each injector has been seated properly.

G. Tighten down the fuel rail assembly with the

original bolts.

H. Use the supplied jumper harnesses to connect

the factory fuel injector plug to the newly installed
fuel injectors. (See

Fig. 7-a.)

Zip tie the jumper harnesses to the fuel rail so the

stay clear of the manifold when reinstalled. (See
Fig. 7-a.)

Reinstall all previously removed components.

Fig. 7-a