| Removal and Installation Special Tool(s) | | Hand Pressure Pump with Adapter Kit 310-110 | | | Gauge Bolt Angle 303-174 (21-540) | General Equipment Pneumatic vacuum gun World Diagnostic System (WDS) (418-F224) 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) valve tube.
For additional information, refer to: Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube.
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Remove the air cleaner.
For additional information, refer to: Air Cleaner - 1.8L Duratorq-TDCi (Lynx) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).
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Remove the turbocharger intake pipe support bracket retaining bolt. | | | -
Detach the fuel injector wiring harness. - Disconnect the fuel injector electrical connectors.
- Press in the injector wiring harness retaining clips. Detach the injector wiring harness and secure to one side.
| 5. Remove the components in the order indicated in the following illustration(s) and table(s). 4 - Camshaft position sensor (CMP) electrical connector 5 - Charge air temperature sensor electrical connector 6 - Manifold absolute pressure (MAP) sensor electrical connector 8 - Charge air cooler bypass pipe retaining clamp 22 - Fuel injector to cylinder head sealing washers | | -
NOTE:Do not install the engine upper cover at this stage. To install, reverse the removal procedure. | | | -
CAUTION:The generator must be protected from contamination. Failure to follow this instruction may cause premature failure of the generator. Protect the generator with lint-free material to prevent contamination. | | | -
Detach the fuel tank to fuel filter 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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NOTE:Make sure 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 union. | | | -
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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Remove the lint-free material. | | | -
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. | | | -
Protect the generator with lint-free material to prevent contamination. | | | -
Connect the fuel tank to fuel filter 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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Remove the lint-free material. | | | -
NOTE:If a set of new fuel injectors are installed that do not have the same fuel injector calibration code as those originally fitted, use WDS Program Module Routine and program the new fuel injectors calibration code into the powertrain control module (PCM). Failure to follow this instruction may cause injector ticking noise, combustion noise and possibly incorrect emissions. Program the PCM with the fuel injector calibration code. | | | -
Install the engine upper cover. | | | -
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 1 : Engine wiring harness retaining clip | | -
Detach the engine wiring harness retaining clip from the engine timing belt upper cover. | Item 2 : Fuel filter supply and return fuel lines support bracket | | -
Detach the fuel filter supply and return lines support bracket from the engine timing belt upper cover. | Item 3 : Timing belt upper cover | | -
Remove the timing belt upper cover. - Remove the timing belt upper cover retaining bolts.
- Slide the timing belt upper cover upwards to disengage the cover retaining tang.
| Item 7 : Intake air shutoff throttle air intake pipe | | -
Disconnect the air intake pipe from the intake air shutoff throttle. | Item 9 : Charge air cooler bypass pipe | | -
Disconnect the charge air bypass pipe from the intake air shutoff throttle. | Item 10 : Intake air shutoff throttle vacuum control pipe | | -
Disconnect the intake air shutoff throttle vacuum control pipe from the intake air shutoff throttle vacuum control actuator. | Item 11 : Charge air cooler bypass vacuum control pipe | | -
Disconnect the charge air cooler bypass vacuum control pipe from the intake air shutoff throttle vacuum actuator. | Item 12 : Positive crankcase ventilation (PCV) oil return hose | | -
Disconnect the PCV oil return hose from the oil filler tube. | Item 13 : PCV breather hose quick release coupling | | -
Disconnect the PCV breather hose from the intake manifold PCV valve. - Press in the release clip.
| Item 15 : Intake manifold CAUTION:Take care not to place excessive strain on the fuel pump fuel supply lines when removing the intake manifold. | | -
Detach the fuel pump fuel supply lines from the intake manifold. | Item 17 : Fuel injector high-pressure fuel supply lines 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. | | -
Clean the fuel injectors, fuel injection supply manifold, high-pressure fuel supply lines and surrounding areas.
For additional information, refer to: Fuel Injection Component Cleaning.
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Detach the high-pressure fuel supply line unions from the fuel injector and the fuel injection supply manifold. | | | -
Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply line, the fuel injector and the fuel injection supply manifold. | | | -
Remove and discard the high-pressure fuel supply lines. | | | -
Install new blanking plugs to the open threaded ports on the fuel injectors and the fuel injection supply manifold. | Item 19 : Fuel injector fuel return pipe connections | | -
Disconnect the fuel injector fuel return pipes. - Pull down the release clip.
- Remove the fuel injector fuel return pipe with a twisting motion.
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Install blanking plugs to the open ends of the fuel return pipes and the fuel injectors. | Installation Details Item 23 : Fuel injector seals | | -
Press the new fuel injector seal into the cylinder head. | Item 21 : Fuel injectors CAUTION:Fuel injectors are in matched sets and all four injectors must have the same calibration code. | | -
NOTE:The example shown is to indicate the location of the code only. Make sure that the fuel injector calibration codes of all four fuel injectors match. | | | -
Make sure the fuel injector retaining bracket retaining clip is correctly installed. | | | -
Remove and discard the blanking cap from the injector nozzle. | Item 20 : Fuel injector retaining bracket nuts | | -
Install the fuel injector retaining bracket nuts finger tight. | Item 19 : Fuel injector fuel return pipe connections | | -
Remove and discard the blanking plugs from the fuel injectors and the fuel injector return pipe connections. | Item 18 : Fuel injector high-pressure fuel supply line support grommets | | -
Install the fuel injector high-pressure fuel supply line support grommets to the cylinder head. | Item 17 : Fuel injector high-pressure fuel supply lines 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: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 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. 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. | | -
Using the pneumatic vacuum gun, vacuum foreign material from the area around the fuel injectors and the fuel injection supply manifold. | | | -
Remove and discard the blanking plugs from the high-pressure fuel supply lines, the fuel injection supply manifold and the fuel injectors. | | | -
Install the fuel injector high-pressure fuel supply lines. - Finger tighten the high-pressure fuel supply line unions.
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NOTE:Tighten the fuel injector retaining bracket nuts so that the fuel injector retaining bracket remains level. Using the special tool tighten the fuel injector retaining bracket nuts in two stages. - Stage 1: 4 Nm
- Stage 2: 45 degrees
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CAUTION:Individual high-pressure fuel supply lines must have both unions tightened before continuing on to the next high-pressure fuel supply line. Failure to follow this instruction may result in damage to the high-pressure fuel supply lines. Tighten the high-pressure fuel supply line unions. | Item 15 : Intake manifold | | -
Install the fuel pump fuel supply line to the intake manifold. | Item 14 : Intake manifold retaining bolts | | -
Tighten the intake manifold retaining bolts in two stages in the sequence shown. | Item 13 : PCV breather hose quick release coupling NOTE:Make sure that the PCV hose and quick release coupling are clean and free from any oil residue. Item 12 : Positive crankcase ventilation (PCV) oil return hose NOTE:Make sure that the PCV oil return hose is clean and free from any oil residue as this will reduce the installation grip of the PCV hose. | 
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