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Fuel Injection Pump > < Fuel Injection Component Cleaning

Fiesta 2002.25 (11.2001-)

Fuel Charging and Controls - 1.4L Duratorq-TDCi (DV) Diesel - Fuel Injectors Fiesta 2002.25 (11/2001-)
Removal and Installation

General Equipment
Pneumatic vacuum gun
Materials
Name
Specification
Grease
WSD-M1C228-A 

Removal

WARNING:
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 ignite. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:Do not carry out any repairs to the fuel injection system with the engine running. The fuel pressure within the system can be as high as 1600 bar. Failure to follow this instruction may result in personal injury.
WARNING:
WARNING:Wait at least one minute after the engine stops before commencing any repair to the fuel injection system. Failure to follow this instruction may result in personal injury.
CAUTION:
CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines.
CAUTION:
CAUTION:Do not disassemble fuel injectors or clean the nozzles, even with an ultrasonic cleaner. Always install new fuel injectors when required.
CAUTION:
CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components to prevent foreign matter ingress to the components.
  1. Disconnect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Remove the intake manifold assembly.
    For additional information, refer to: Intake Manifold (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).

  1. Disconnect the glow plug electrical connectors.
  1. Clean the fuel injection supply manifold, high-pressure fuel supply line and surrounding areas.
    For additional information, refer to: Fuel Injection Component Cleaning (303-04C Fuel Charging and Controls - 1.4L Duratorq-TDCi (DV) Diesel, General Procedures).

  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel pump and the fuel injection supply manifold until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    Remove and discard the high-pressure fuel supply line.
  1. Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply line, the fuel pump and the fuel injection supply manifold.
  1. Install blanking caps to the open threaded ports on the fuel pump and the fuel injection supply manifold.
  1. Clean the fuel injector, fuel injection supply manifold, high-pressure fuel supply line and surrounding areas.
    For additional information, refer to: Fuel Injection Component Cleaning (303-04C Fuel Charging and Controls - 1.4L Duratorq-TDCi (DV) Diesel, General Procedures).

  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel injector and the fuel injection supply manifold until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    Detach the high-pressure fuel supply line unions from the fuel injector and the fuel injection supply manifold.
  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel injector and the fuel injection supply manifold until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply line, the fuel injector and the fuel injection supply manifold.
  1. Remove and discard the high-pressure fuel supply line.
  1. Install blanking plugs to the open threaded ports on the fuel injector and the fuel injection supply manifold.

  1. Disconnect the fuel return line from the fuel injector.
    1. Release the locking clip.
    1. Pull the fuel return line.
  1. Clean the area around the fuel injector.
    For additional information, refer to: Fuel Injection Component Cleaning (303-04C Fuel Charging and Controls - 1.4L Duratorq-TDCi (DV) Diesel, General Procedures).

  1. Remove the fuel injector and clamp.
    • Discard the retaining bolt and the copper sealing washer.

Installation

WARNING:
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 can ignite. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions.
CAUTION:
CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always fit blanking plugs to any open orifices or lines.
CAUTION:
CAUTION:Always carry out the cleaning process before carrying out any repairs to fuel system components to prevent foreign matter ingress to the components.
NOTE:
NOTE:Install a new fuel injector copper sealing washer.
NOTE:
NOTE:Install a new fuel injector clamp retaining bolt.
NOTE:
NOTE:Install a new high-pressure fuel supply line.
  1. Remove the blanking plug from the fuel injector nozzle and install the fuel injector and clamp.
    • Discard the blanking plug.

  1. Lubricate the fuel return line connector using grease and connect the fuel return line to the fuel injector.
    1. Install the locking clip.
    1. Install the fuel return line.

  1. CAUTION:
    CAUTION:Do not allow the unions to hit the ends of the high-pressure fuel supply line. Failure to follow this instruction may result in damage to the ends of the line and allow foreign material to enter the fuel injection system.
    CAUTION:
    CAUTION:Remove the blanking plugs from the high-pressure fuel supply line, the fuel injector and the fuel injection supply manifold at the last possible moment. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    CAUTION:
    CAUTION:Make sure the tool used to tighten the high-pressure fuel supply line unions is used at the top of the unions as this is where there is most material. Failure to follow this instruction may result in damage to the unions.
    NOTE:
    NOTE:Maintain pressure on the high-pressure fuel supply line to keep the line in contact with the fuel injector cone and fuel injection supply manifold while installing the unions.
    NOTE:
    NOTE:If it is not possible to correctly install the new high-pressure fuel supply line, it will be necessary to remove the remaining high-pressure fuel supply lines and to loosen the fuel injection supply manifold to allow correct alignment.
    Install a new high-pressure fuel supply line.
    • Tighten the unions in 2 stages.
    • Stage 1: Tighten the unions - 17 Nm.
    • Stage 2: Tighten the unions - 22 Nm.
    • Discard the blanking plugs.

  1. CAUTION:
    CAUTION:Do not allow the unions to hit the ends of the high-pressure fuel supply line. Failure to follow this instruction may result in damage to the ends of the line and allow foreign material to enter the fuel injection system.
    CAUTION:
    CAUTION:Remove the blanking plugs from the high-pressure fuel supply line, the fuel pump and the fuel injection supply manifold at the last possible moment. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    CAUTION:
    CAUTION:Make sure the tool used to tighten the high-pressure fuel supply line unions is used at the top of the unions as this is where there is most material. Failure to follow this instruction may result in damage to the unions.
    NOTE:
    NOTE:Maintain pressure on the high-pressure fuel supply line to keep the line in contact with the fuel injector pump and the fuel injection supply manifold while installing the unions.
    NOTE:
    NOTE:If it is not possible to correctly install the new high-pressure fuel supply line, it will be necessary to remove the remaining high-pressure fuel supply lines and to loosen the fuel injection supply manifold to allow correct alignment.
    Install a new high-pressure fuel supply line.
    • Tighten the unions in 2 stages.
    • Stage 1: Tighten the unions - 17 Nm.
    • Stage 2: Tighten the unions - 22 Nm.
    • Discard the blanking plugs.

  1. Connect the glow plug electrical connectors.
  1. Install the intake manifold assembly.
    For additional information, refer to: Intake Manifold (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
  1. Connect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

Fuel Injection Pump > < Fuel Injection Component Cleaning