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Fuel Metering Valve > < Fuel Injection Pump

Fiesta 2002.25 (11.2001-)

Fuel Charging and Controls - 1.4L Duratorq-TDCi (DV) Diesel - Fuel Injection Supply Manifold Fiesta 2002.25 (11/2001-)
Removal and Installation

General Equipment
Pneumatic vacuum gun

Removal

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:Do not carry out any repairs to the fuel injection system without checking that the fuel pressure has dropped to zero and that the fuel temperature is below 30 degrees C. 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 injection supply manifold, even with an ultrasonic cleaner. Always install a new fuel injection supply manifold 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.
  1. Disconnect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Remove the intake manifold assembly. For additional information, refer to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine / 303-01E Engine.

  1. Disconnect the glow plug wire.
  1. Clean the fuel injection supply manifold, high-pressure fuel supply lines, injectors and surrounding areas.
    For additional information, refer to Fuel Component Cleaning in this section.
  1. 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. 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 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.
    Remove the high-pressure fuel supply lines in the sequence shown.
    • Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply line, the fuel pump and the fuel injection supply manifold.
    • Install blanking plugs to the open threaded ports on the fuel injector and the fuel injection supply manifold after removing each individual high-pressure fuel supply line.

  1. Detach the fuel injection supply manifold from the cylinder head.

  1. Disconnect the fuel pressure sensor electrical connector and remove the fuel injection supply manifold.

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: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 new high-pressure fuel supply lines.
  1. Connect the fuel pressure sensor electrical connector.

  1. Install the fuel injection supply manifold to the cylinder head.

  1. CAUTION:
    CAUTION:Do not allow the unions to hit the olive ends of the high-pressure fuel supply line as this may damage 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 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:
    CAUTION:Maintain pressure on the high pressure fuel supply line to keep the olive in contact with both the fuel injector cone and the fuel injection supply manifold while hand installing the union. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    NOTE:
    NOTE:Do not tighten the high-pressure line unions at this stage.
    Install the high-pressure fuel supply lines in the sequence shown.
    • Discard the blanking plugs.

  1. Tighten the high-pressure fuel supply lines.
    • Tighten the unions in 2 stages.
    • Stage 1: Tighten the unions - 17 Nm.
    • Stage 2: Tighten the unions - 22 Nm.

  1. CAUTION:
    CAUTION:Do not allow the unions to hit the olive ends of the high-pressure fuel supply line as this may damage 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 pump 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:
    CAUTION:Maintain pressure on the high pressure fuel supply line to keep the olive in contact with both the fuel pump cone and the fuel injection supply manifold while hand installing the union. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    Install the 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 glow plug wire.
  1. Install the intake manifold assembly. For additional information, refer to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01D Engine / 303-01E Engine.
  1. Connect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

Fuel Metering Valve > < Fuel Injection Pump