ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
Fuel Injection Supply Manifold > < Fuel Injectors

Fiesta 2002.25 (11.2001-)

Fuel Charging and Controls - 1.4L Duratorq-TDCi (DV) Diesel - Fuel Injection Pump Fiesta 2002.25 (11/2001-)
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)

Removal

  1. 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 these instructions 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 these instructions 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 or clean inside the fuel pump, even with an ultrasonic cleaner. Always install a new fuel pump when required.
    CAUTION:
    CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    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 air cleaner.
    For additional information, refer to: Air Cleaner - 1.4L Duratorq-TDCi (DV) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Remove the timing belt.
    For additional information, refer to: Timing Belt (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).

  1. Remove the exhaust gas recirculation (EGR) tube elbow retaining screws.

  1. Remove the EGR tube clamp and the EGR tube.

  1. Disconnect the fuel temperature sensor electrical connector, the fuel pump fuel supply and fuel return lines and secure them to one side.
    • Install blanking plugs to the fuel pump fuel supply and fuel return line female connectors and the fuel pump.

  1. Disconnect the fuel flow control valve electrical connector.

  1. Disconnect the fuel pressure control valve electrical connector and detach the wiring loom (shown from below for clarity).

  1. Remove the fuel pump support bracket.
  1. Clean the fuel pump, 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.
    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. 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 fuel pump and the fuel injection supply manifold.
  1. Install blanking plugs to the open threaded ports on the fuel pump and the fuel injection supply manifold.
  1. Assemble the flange holding wrench (205-072) and the adaptors (205-07202) using two 13 mm nuts.

  1. Using the special tools, hold the fuel pump pulley and remove the retaining nut.

  1. 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.

  1. NOTE:
    NOTE:Support the fuel pump.
    Remove the fuel pump retaining bolts.

  1. Remove the fuel pump.

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 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.
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 or clean inside the fuel pump, even with an ultrasonic cleaner. Always install a new fuel pump when required.
CAUTION:
CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
NOTE:
NOTE:Install a new high-pressure fuel supply line.
  1. NOTE:
    NOTE:Do not tighten the fuel pump retaining bolts at this stage.
    Install the fuel pump.

  1. Install the fuel pump support bracket

  1. Tighten the fuel pump retaining bolts.
  1. Install the fuel pump pulley.

  1. Using the special tools, tighten the fuel pump pulley retaining nut.
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 matter ingress to the fuel injection system.
CAUTION:
CAUTION:Remove the blanking plugs from the high-pressure fuel supply line, the fuel injection supply manifold and the fuel pump 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.
  1. 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 fuel pressure control valve electrical connector and install the wiring loom (shown from below for clarity).

  1. Connect the fuel flow control valve electrical connector.

  1. Connect the fuel temperature sensor electrical connector, the fuel pump fuel supply and fuel return lines.
    • Discard the blanking plugs.

  1. Install the EGR tube and the EGR tube clamp.

  1. Install the EGR tube elbow retaining screws.
  1. Install the timing belt.
    For additional information, refer to: Timing Belt (303-01B Engine - 1.4L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).

  1. Disconnect the fuel pump fuel return line from the fuel tank fuel return line.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Remove the fuel filter shield.
  1. Clean the area around the fuel filter connections and fuel lines.
    For additional information, refer to: Fuel Injection Component Cleaning (303-04C Fuel Charging and Controls - 1.4L Duratorq-TDCi (DV) Diesel, General Procedures).

  1. Connect the fuel pump fuel return line to the fuel tank fuel return line.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Disconnect the fuel tank to fuel filter fuel supply line from the fuel filter.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Install the hand pressure pump special tool adaptor to the fuel filter.

  1. Install the hand pressure pump special tool adaptor to the fuel tank to fuel filter fuel supply line.

  1. NOTE:
    NOTE:Make sure the hand primer special tool arrow indicating the direction of fuel flow is pointing towards the fuel filter.
    Install the hand pressure pump special tool to the hand pressure pump special tool adaptors.
  1. Operate the hand pressure pump special tool until fuel starts to flow through the fuel filter.

  1. Disconnect the hand pressure pump special tool adaptor from the fuel tank to fuel filter fuel supply line.

  1. Disconnect the hand pressure pump special tool adaptor from the fuel filter.

  1. Connect the fuel tank to fuel filter fuel supply line to the fuel filter.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Disconnect the fuel pump fuel return line from the fuel tank fuel return line.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Install the fuel filter shield.

  1. Connect the fuel pump fuel return line to the fuel tank fuel return line.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
  1. Install the air cleaner.
    For additional information, refer to: Air Cleaner - 1.4L Duratorq-TDCi (DV) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  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 Supply Manifold > < Fuel Injectors