| Removal and Installation Special Tool(s) | | Flange Holding Wrench, Universal 205-072 (15-030 A) | | | Adaptors for 205-072 205-07202 (15-030 A-02) | | | Remover, Crankshaft Timing Sprocket 303-249 (21-132) | | | Hand Pressure Pump with Adapter Kit 310-110 | General Equipment Pneumatic vacuum gun Two 13 mm nuts Two M7x50 mm long bolts (use camshaft bearing cap retaining bolts as used in the 1.4L Duratec-16V (Sigma) engine) 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: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: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: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: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:Do not disassemble fuel injectors or clean the nozzles, even with an ultrasonic cleaner. Always install new fuel injectors when required. 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. | | -
Disconnect the battery ground cable.
For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
| 2. Remove the components in the order indicated in the following illustration(s) and table(s). 1 - Fuel injector wiring harness trunking retaining bolts 2 - Fuel injector electrical connectors 3 - Fuel injector fuel return line 4 - Camshaft position (CMP) sensor electrical connector 5 - Fuel temperature sensor electrical connector 8 - Fuel pump electrical connector 10 - Glow plug wire connectors 18 - Fuel pump high-pressure fuel supply line support bracket retaining bolt 19 - Fuel pump high-pressure fuel supply line support bracket 23 - Fuel pump fuel line retaining bracket 3. To install, reverse the removal procedure. | | -
Using the special tool, prime the fuel system. - Operate the hand pump until it becomes firm when squeezed.
- Squeeze and hold the hand pump for 10 seconds.
- Release the hand pump.
- Squeeze and hold the hand pump for a further 10 seconds.
- Release the hand pump.
| | | -
CAUTION:Do not operate the starter motor for longer than 10 seconds at a time. After 10 seconds, turn the ignition to position 0 and allow the starter motor to cool for 30 seconds before attempting to start the engine again. Start the engine and allow to idle until it reaches normal operating temperature. | | | -
Remove the special tool and connect the fuel supply line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
| Removal Details Item 6 : Glow plug wire electrical connector | | -
Disconnect the glow plug loom electrical connector and detach the glow plug wire electrical connector from the retaining bracket. | Item 7 : Fuel line retaining clips | | -
Detach the fuel lines from the fuel line retaining clips. | Item 9 : Fuel lines | | -
Position the fuel lines to one side. | Item 11 : Fuel pump fuel supply line quick release coupling | | -
Clean the fuel pump, fuel pump fuel supply line quick release coupling, and surrounding areas.
For additional information, refer to: Fuel Injection Component Cleaning (303-04F Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, General Procedures).
| | | -
Disconnect the fuel pump fuel supply line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
| | | -
Install new blanking plugs to the open ends of the fuel pump fuel supply line quick release coupling and fuel pump. | Item 12 : Fuel pump fuel return line quick release coupling | | -
Clean the fuel pump, fuel pump fuel return line quick release coupling, and surrounding areas.
For additional information, refer to: Fuel Injection Component Cleaning (303-04F Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, General Procedures).
| | | -
Disconnect the fuel pump fuel return line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
| | | -
Install new blanking plugs to the open ends of the fuel pump fuel return line quick release coupling and fuel pump. | Item 13 : Fuel pump to fuel tank fuel return line quick release coupling | | -
Disconnect the fuel pump to fuel tank fuel return line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
| | | -
Install new blanking plugs to the open ends of the fuel pump to fuel tank fuel return line quick release coupling. | Item 14 : Fuel tank to fuel filter fuel supply line quick release coupling | | -
Disconnect the fuel pump to fuel tank to fuel filter fuel supply line quick release coupling and remove the fuel lines.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
| | | -
Install new blanking plugs to the open ends of the fuel tank to fuel filter fuel supply line quick release coupling and fuel filter. | Item 15 : Timing belt | | -
Remove the timing belt.
For additional information, refer to: Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
| Item 16 : Fuel pump pulley retaining nut | | -
Assemble the flange holding wrench (205-072) and the adaptors (205-07202) using two 13 mm nuts. | | | -
Using the special tools, hold the fuel pump pulley and remove the retaining nut. | Item 17 : Fuel pump pulley | | -
Using the special tool with two M7x50 mm long bolts (use camshaft bearing cap retaining bolts as used in the 1.4L Duratec-16V (Sigma) engine), remove the fuel pump pulley. | Item 20 : Fuel pump high-pressure fuel supply line 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. | | -
Clean the fuel pump, fuel rail, high-pressure fuel supply line and surrounding areas.
For additional information, refer to: Fuel Injection Component Cleaning (303-04F Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, General Procedures).
| | | -
Detach the high-pressure fuel supply line unions from the fuel pump and the fuel injection supply manifold. | | | -
Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply line, the fuel pump and the fuel injection supply manifold. | | | -
Remove and discard the high-pressure fuel supply line. | | | -
Install blanking plugs to the open threaded ports on the fuel pump and the fuel rail. | Item 22 : Fuel pump | | -
Support the fuel pump while removing the fuel pump retaining bolts. | Installation Details Item 21 : Fuel pump support bracket | | -
NOTE:Do not tighten the fuel pump support bracket retaining bolts at this stage. Loosely install the fuel pump support bracket retaining bolts. | Item 20 : Fuel pump high-pressure fuel supply line CAUTION:Remove the blanking plugs from the high-pressure fuel supply line and fuel rail at the last possible moment. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system. 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:Make sure that 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: 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. | | -
Using the pneumatic vacuum gun, vacuum foreign material from the area around the injectors and the injection supply manifold. | | | -
Remove and discard the blanking plugs from the high-pressure fuel supply lines and fuel rail. | | | -
Tighten the fuel pump high-pressure fuel supply line unions in two stages. | Item 16 : Fuel pump pulley retaining nut | | -
Using the special tools, tighten the fuel pump pulley retaining nut. | | | -
Tighten the fuel pump support bracket retaining bolts. | Item 15 : Timing belt | | -
Install the timing belt.
For additional information, refer to: Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
| Item 14 : Fuel tank to fuel filter fuel supply line quick release coupling | | -
Remove the blanking plugs from the open ends of the fuel tank to fuel filter fuel supply line quick release coupling and fuel filter. | | | -
NOTE:Make sure that the hand pressure pump arrow indicating the direction of fuel flow is pointing towards the fuel filter. Install the special tool between the fuel tank fuel supply line quick release coupling and the fuel filter. | Item 13 : Fuel pump to fuel tank fuel return line quick release coupling | | -
Remove the blanking plugs from the open ends of the fuel pump to fuel tank fuel return line quick release coupling. | | | -
Connect the fuel pump to fuel tank fuel return line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
| Item 12 : Fuel pump fuel return line quick release coupling | | -
Remove the blanking plugs from the open ends of the fuel pump fuel return line quick release coupling. | | | -
Connect the fuel pump fuel return line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
| Item 11 : Fuel pump fuel supply line quick release coupling | | -
Remove the blanking plugs from the open ends of the fuel pump fuel supply line quick release coupling. | | | -
Connect the fuel pump fuel supply line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
| |
 Diesel/Description and Operation/Diagnosis and Testing/General Procedures/Removal and Installation//img/310110.jpg)
 Diesel/Description and Operation/Diagnosis and Testing/General Procedures/Removal and Installation//img/E41118.jpg)
 Diesel/Description and Operation/Diagnosis and Testing/General Procedures/Removal and Installation//img/E39288.jpg)
 Diesel/Description and Operation/Diagnosis and Testing/General Procedures/Removal and Installation//img/E0027046.jpg)
 Diesel/Description and Operation/Diagnosis and Testing/General Procedures/Removal and Installation//img/E39365.jpg)
 Diesel/Description and Operation/Diagnosis and Testing/General Procedures/Removal and Installation//img/E0029981.jpg)
 Diesel/Description and Operation/Diagnosis and Testing/General Procedures/Removal and Installation//img/E40859.jpg)
