| 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. | | -
Remove the exhaust gas recirculation (EGR) cooler.
For additional information, refer to: Exhaust Gas Recirculation (EGR) Cooler (303-08C Engine Emission Control - 1.6L Duratorq-TDCi (DV) Diesel, Removal and Installation).
| 2. Remove the components in the order indicated in the following illustration(s) and table(s). 4 - Fuel filter fuel supply line and fuel pump fuel return line retaining clip See Removal Detail 10 - Fuel injection system fuel supply and fuel return lines 16 - Fuel pump high-pressure fuel supply line support bracket retaining bolt 18 - Fuel pump fuel pressure control valve electrical connector 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.
- Squeeze and hold the hand pump for a further 10 seconds.
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CAUTION:Do not operate the starter motor for longer than 10 seconds at a time. After 10 seconds, turn the ignition key 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 it to idle until it reaches normal operating temperature. | | | -
Remove the hand pressure pump 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).
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Initialize the door window motors.
For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).
| Removal Details Item 2 : Fuel supply line quick release coupling | | -
Clean the fuel injector, fuel rail, high-pressure fuel supply line and surrounding areas.
For additional information, refer to: Fuel Injection Component Cleaning (303-04G Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel, General Procedures).
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Detach the fuel supply line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
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Install new blanking plugs to the open ends of the fuel supply line and fuel filter fuel supply pipe. | Item 3 : Fuel line quick release coupling
Item 6 : Fuel line quick release coupling
Item 7 : Fuel line quick release coupling
Item 8 : Fuel line quick release coupling
Item 9 : Fuel line quick release coupling | | -
Detach the quick release couplings.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
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Install new blanking plugs to the open ends of the fuel supply line, fuel filter, fuel pump and fuel supply line. | Item 4 : Fuel filter fuel supply line and fuel pump fuel return line retaining clip | | -
Detach the fuel filter fuel supply line and fuel pump fuel return line from the intake manifold. | Item 5 : Fuel injector fuel return line connections | | -
Detach the fuel return line from the fuel injector. - Remove the fuel return line retaining clip.
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Install blanking plugs to the open ends of the fuel return lines and the fuel injectors. | Item 11 : Glow plug wire electrical connector | | -
Disconnect the glow plug wiring harness electrical connector and detach the glow plug wire electrical connector from the retaining bracket. | Item 13 : Timing belt | | -
Remove the timing belt.
For additional information, refer to: Timing Belt (303-01D Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
| Item 14 : 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 15 : 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 17 : 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 rail 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 (303-04G Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel, General Procedures).
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Detach the high-pressure fuel supply line unions from the fuel pump and the fuel rail. | | | -
Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply line, the fuel pump and the fuel rail. | | | -
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 20 : Fuel pump | | -
Support the fuel pump while removing the fuel pump retaining bolts. | Installation Details Item 19 : Fuel pump support bracket | | -
Install the fuel pump support bracket retaining bolt finger tight. | Item 17 : Fuel pump high-pressure fuel supply line CAUTION:Remove the blanking plugs from the high-pressure fuel supply line, the fuel pump and the 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 pump and fuel rail while installing the unions. | | -
Using the pneumatic vacuum gun, vacuum foreign material from the area around the fuel pump and the fuel rail. | | | -
Remove and discard the blanking plugs from the high-pressure fuel supply lines, the fuel rail and the fuel pump. | | | -
Tighten the fuel pump high-pressure fuel supply line unions in two stages. | Item 14 : Fuel pump pulley retaining nut | | -
Using the special tools, tighten the fuel pump pulley retaining nut. | Item 13 : Timing belt | | -
Install a new timing belt.
For additional information, refer to: Timing Belt (303-01D Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
| Item 9 : Fuel line quick release coupling
Item 8 : Fuel line quick release coupling
Item 7 : Fuel line quick release coupling
Item 6 : Fuel line quick release coupling
Item 3 : Fuel line quick release coupling | | -
Remove and discard the blanking plugs from the fuel pipe quick release couplings and fuel components. | | | -
Connect the fuel line quick release couplings.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
| Item 5 : Fuel injector fuel return line connections | | -
Remove and discard the blanking plugs from the fuel injectors and the fuel injector return line connections. | Item 2 : Fuel supply line quick release coupling | | -
NOTE:Make sure that the hand pressure pump arrow indicating the direction of fuel flow is pointing towards the fuel filter. Remove and discard the blanking plugs. Install the special tool between the fuel tank fuel supply line quick release coupling and the fuel injection fuel supply pipe union. | |
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