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Fuel Metering Valve > < Fuel Injection Timing Solenoid

Focus 1999 (08.1998-12.2004)

Fuel Charging and Controls - 1.8L Diesel (75 PS/90 PS) - Fuel Injection One-Way Valve Focus 1999 (08/1998-12/2004)
Removal and Installation

Special Tool(s)

Hand Pressure Pump with Adapter Kit

310-110
General Equipment
Pneumatic vacuum gun
Small screwdriver

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.
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.
  1. Remove the air deflector.

  1. NOTE:
    NOTE:Make a note of the orientation of the charge air cooler intake hose retaining clamp.
    Disconnect the charge air cooler intake hose.
    • Discard the charge air cooler intake hose retaining clamp.

  1. NOTE:
    NOTE:Make a note of the orientation of the charge air cooler outlet hose retaining clamp.
    Disconnect the charge air cooler outlet hose and the intake air temperature (IAT) sensor electrical connector.
    • Discard the charge air cooler outlet hose retaining clamp.

  1. Remove the charge air cooler.
  1. CAUTION:
    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.
  1. Using the pneumatic vacuum gun, clean the area around the high-pressure fuel supply lines.

  1. Disconnect the high-pressure fuel supply lines from the fuel injection pump.
  1. Using the pneumatic vacuum gun, clean the area around the high-pressure fuel supply lines.

  1. Remove the high-pressure fuel supply lines.
    • Discard the supply lines.

  1. NOTE:
    NOTE:Fuel injection pump shown removed for clarity.
    Remove the fuel injection one-way valves.
    • Discard the fuel injection one-way valves.

  1. NOTE:
    NOTE:Fuel injection pump shown removed for clarity.
    Using a clean small screwdriver, carefully remove the sealing washers.
    • Discard the sealing washers.

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.
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.
  1. Lubricate the fuel injection one-way valves with Renap 220 oil (supplied in the parts kit).

  1. Position the sealing washers onto the end of the fuel injection one-way valves.

  1. NOTE:
    NOTE:Fuel injection pump shown removed for clarity.
    Install the fuel injection one-way valves.
  1. CAUTION:
    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.

  1. NOTE:
    NOTE:Install new high-pressure fuel supply lines.
    NOTE:
    NOTE:Do not tighten the high-pressure fuel supply lines at this stage.
    Connect the high-pressure fuel supply lines to the fuel injection pump.

  1. NOTE:
    NOTE:Do not tighten the high-pressure fuel supply lines at this stage.
    Connect the high-pressure fuel supply lines to the fuel injectors.

  1. NOTE:
    NOTE:Install new high-pressure fuel supply lines.
    Tighten the high-pressure fuel supply lines to the fuel injection pump.

  1. Disconnect the fuel tank to fuel filter fuel supply line from the fuel filter.

  1. CAUTION:
    CAUTION:Make sure that the fuel filter connection is not damaged with the installation of the special tool, as this may cause air ingress to fuel lines.
    Install the hand pressure pump special tool adapter to the fuel filter.

  1. NOTE:
    NOTE:Make sure that the hand primer 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 adapter on the fuel filter.

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

  1. NOTE:
    NOTE:Make sure that the hand primer 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 adapter on the fuel tank to fuel filter fuel supply line.
  1. Operate the fuel hand pressure pump special tool until fuel starts to flow through the fuel filter and fuel pump and the hand pressure pump special tool becomes firm.

  1. NOTE:
    NOTE:Only one high-pressure fuel supply line will show signs of fuel escaping.
    Operate the hand pressure pump special tool and tighten the high-pressure fuel supply line union which shows signs of fuel escaping.
  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Using the paint mark as a reference, slowly turn the engine through 180 degrees.
  1. Repeat steps 14 and 15 to bleed the three remaining high-pressure fuel supply lines.
  1. Remove the lint-free material from the generator.
  1. CAUTION:
    CAUTION:Do not operate the starter motor for more than 10 seconds at a time. After 10 seconds, turn the ignition switch 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.
  1. Switch the engine off.

  1. Remove the hand pressure pump special tool from the hand pressure pump special tool adapter on the fuel tank to fuel filter fuel supply line.

  1. Remove the hand pressure pump special tool adapter from the fuel tank to fuel filter fuel supply line.

  1. Remove the hand pressure pump special tool from the hand pressure pump special tool adapter on the fuel filter.

  1. Remove the hand pressure pump special tool adapter from the fuel filter.

  1. Connect the fuel tank to fuel filter fuel supply line to the fuel filter.

  1. Install the charge air cooler.

  1. NOTE:
    NOTE:Install a new charge air cooler outlet hose retaining clamp.
    NOTE:
    NOTE:Make sure the charge air cooler outlet hose retaining clamp is in the same orientation as when removed.
    Connect the charge air cooler outlet hose and the IAT sensor electrical connector.

  1. NOTE:
    NOTE:Install a new charge air cooler intake hose retaining clamp.
    NOTE:
    NOTE:Make sure the charge air cooler intake hose retaining clamp is in the same orientation as when removed.
    Connect the charge air cooler intake hose.

  1. Install the air deflector.

Fuel Metering Valve > < Fuel Injection Timing Solenoid