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Fuel Injection Pump - 1.8L Endura-DI (Lynx) Diesel > < Fuel Injectors - 1.8L Endura-DI (Lynx) Diesel

Fiesta 1996 (08.1995-02.2002)

Fuel Charging and Controls - 1.8L Diesel - Fuel Injection Pump Fiesta 1996 (08/1995-02/2002)
Removal and Installation

Special Tool(s)

Timing Peg, Crankshaft TDC

303-193 (21-104)

Support Bar, Engine

303-290 (21-140)

Adapter for 303-290

303-290-01 (21-140-01)

Adapter for 303-290

303-290-02 (21-140-02)

Adapter for 303-290

303-290-03 (21-140-03)

Timing Peg, Fuel Injection Pump Timing

310-018 (23-019)

Timing Peg, Fuel Injection Pump Timing

310-033 (23-029)

Removal

All vehicles
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 pipes.
  1. Disconnect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. Install the special tools.

  1. Remove the engine front mounting auxiliary bracket.

  1. Remove the engine front mounting bracket.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Loosen the crankshaft pulley/vibration damper retaining bolts.
  1. Remove the generator. For additional information, refer to Section  414-02 Generator and Regulator.

  1. Remove the crankshaft pulley/vibration damper.

  1. Remove the timing belt lower cover retaining bolts.
  1. Lower the vehicle.
Vehicles with power steering
  1. Loosen the power steering pump pulley retaining bolts.

  1. Detension the accessory drive belt.
    1. Loosen the Allen bolt.
    1. Detension the belt.

  1. Remove the accessory drive belt.

  1. Remove the power steering pump pulley.
All vehicles
  1. Remove the timing belt cover.

  1. Turn the engine clockwise until the slot in the fuel injection pump pulley reaches the 11 o'clock position.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the blanking plug from the cylinder block. (Generator bracket shown removed for clarity).

  1. Install the special tool to the cylinder block.
    CAUTION:
    CAUTION:When turning the engine to lock the crankshaft, do so slowly to avoid bending the special tool.
    Turn the engine clockwise until the crankshaft locks against the special tool.

  1. Install the special tool, to lock the camshaft.

  1. Install the special tool, to lock the fuel injection pump.
  1. Remove and discard the timing belt. For additional information, refer to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine / 303-01E Engine.

  1. Remove the accelerator cable adjuster clip.

  1. Detach the accelerator cable from the retaining bracket.

  1. Disconnect the accelerator cable from the fuel injection pump fuel lever.
Vehicles without air conditioning
  1. Remove the waxstat cable retaining clip.

  1. Disconnect the waxstat cable from the fuel injection pump idle lever.
Vehicles with air conditioning
  1. Remove the idle speed compensation cable retaining clip.

  1. Disconnect the idle speed compensation cable from the fuel injection pump idle lever.
All vehicles
  1. Detach the fuel injection pump wiring from the retaining clip and disconnect the electrical connector.

  1. Disconnect the fuel return line from the fuel injection pump.

  1. Disconnect the fuel supply and return lines from the fuel injection pump.

  1. Remove the fuel injector leak-off pipes.

  1. Detach the fuel return line from the retaining clips.

  1. Remove the fuel injector fuel supply line unions from the fuel injection pump.

  1. Remove the fuel injector fuel supply line unions from the fuel injectors.

  1. Loosen the fuel injection pump drive belt tensioner bolt.

  1. Detension the fuel injection pump drive belt.

  1. Tighten the fuel injection pump drive belt tensioner bolt.

  1. Loosen the fuel injection pump pulley retaining bolts.

  1. Remove the fuel injection pump drive belt.
    • Discard the fuel injection pump drive belt.
  1. Remove the special tool from the fuel injection pump.

  1. Remove the fuel injection pump pulley.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the three bolts which retain the fuel injection pump rear support bracket to the cylinder block.
  1. Lower the vehicle.

  1. CAUTION:
    CAUTION:Before removing the three bolts which retain the fuel injection pump to the front cover, make sure that the fuel injection pump is adequately supported.
    Remove the fuel injection pump.

  1. Remove the fuel injection pump from the rear support bracket.

Installation

All vehicles
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 pipes.
  1. Install the fuel injection pump rear support bracket.
    • Do not tighten the bolts at this stage.

  1. Install the fuel injection pump.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Install the three bolts which retain the fuel injection pump rear support bracket to the cylinder block.
  1. Lower the vehicle.

  1. Tighten the rear support bracket bolts.

  1. Install the fuel injection pump pulley.
    • Do not tighten the bolts at this stage.

  1. Install the special tool to lock the fuel injection pump.

  1. Install a new fuel injection pump drive belt.

  1. Loosen the bolt and allow the tensioner to tension the fuel injection pump drive belt.

  1. Tighten the fuel injection pump drive belt tensioner bolt.

  1. Tighten the fuel injection pump pulley retaining bolts.
    • Make sure that the elongated holes in the fuel injection pump pulley are centralized with the retaining bolts.
  1. Install a new timing belt. For additional information, refer to Section  301-01C .

  1. Remove the special tool from the fuel injection pump.

  1. Remove the special tool from the camshaft.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the special tool from the cylinder block.
  1. Lower the vehicle.

  1. Turn the engine clockwise two full turns until the slot in the fuel injection pump pulley reaches the 11 o'clock position.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Install the special tool to the cylinder block.
    CAUTION:
    CAUTION:When turning the engine to lock the crankshaft, do so slowly to avoid bending the special tool.
    Turn the engine clockwise until the crankshaft locks against the special tool.
  1. Remove the special tool from the cylinder block.

  1. Loosly install the fuel injector fuel supply line unions to the fuel injectors.

  1. Loosely install the fuel injector fuel supply line unions to the fuel injection pump.

  1. Tighten the fuel injector fuel supply line unions to the fuel injectors.

  1. Tighten the fuel injector fuel supply line unions to the fuel injection pump.

  1. Install the remainder of the components in reverse order.

  1. Adjust the accelerator cable. For additional information, refer to Section  310-02 Acceleration Control.
  1. Check the engine idle speed and adjust as necessary.
    For additional information, refer to Idle Speed Adjustment in this section.
Vehicles without air conditioning
  1. Remove the waxstat cable retaining clip.
  1. NOTE:
    NOTE:This adjustment must be carried out with the engine cold.
    Hold the fuel injection pump idle lever against its stop and install the retaining clip, so that there is between 1 mm and 2 mm of slack in the waxstat cable.
Vehicles with air conditioning
  1. Adjust the idle speed compensation cable (refer to FDS 2000).

Fuel Injection Pump - 1.8L Endura-DI (Lynx) Diesel > < Fuel Injectors - 1.8L Endura-DI (Lynx) Diesel