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Fuel Pump > < Fuel Injectors - VIN Plate Emission Level Code: S

Focus 2004.75 (07.2004-)

Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel - Fuel Injection Supply Manifold—VIN Plate Emission Level Code: S Focus 2004.75 (07/2004-)
Removal and Installation

General Equipment
Pneumatic vacuum gun
World Diagnostic System (WDS)
Screwdriver
Long nosed pliers
Fluid container
Piece of clear tube
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 this instruction 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 this instruction may result in personal injury.
CAUTION:
CAUTION:Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign material from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfunction.
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 material ingress to the fuel injection system.
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 fuel injectors or clean the nozzles, even with an ultrasonic cleaner. Always install new fuel injectors when required.
  1. Using datalogger in WDS, check that the fuel pressure has dropped to zero and that the fuel temperature has either reached ambient air temperature or is below 30°C, whichever is greater.

  1. Note the location of the engine cover retaining clips.

  1. CAUTION:
    CAUTION:Care must be taken when releasing the fourth retaining clip and maneuvering the engine cover past the manifold absolute pressure (MAP) sensor. Failure to follow this instruction may result in damage to the MAP sensor.
    NOTE:
    NOTE:Remove the engine cover in the sequence shown.
    Remove the engine cover.
  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. CAUTION:
    CAUTION:Protect the fuel pressure regulator and fuel metering valve electrical connectors to prevent contamination with the cleaning fluid.
    Clean the fuel pump, fuel rail, high pressure fuel supply line and surrounding areas.
    For additional information, refer to: Fuel Injection Component Cleaning (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, General Procedures).

6. Remove the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Fuel pump fuel supply line retaining clips
See Removal Detail
2
-
Positive crankcase ventilation (PCV) hose retaining clamp
See Removal Detail
3
-
PCV hose
4
-
PCV hose retaining clamp
See Removal Detail
5
-
PCV hose

 
Item
Part Number
Description
6
-
Fuel rail high-pressure fuel supply line
See Removal Detail
See Installation Detail
7
-
Fuel rail pressure (FRP) sensor electrical connector
8
-
Fuel injector high-pressure fuel supply lines
See Removal Detail
See Installation Detail
9
-
Fuel rail retaining bolts
See Installation Detail
10
-
Fuel rail
NOTE:
NOTE:Do not install the engine cover at this stage.
  1. Remove the fuel filter crash protection top shield.

  1. Connect a suitable clean piece of clear tube to the fuel filter bleed screw.
  1. Position the piece of clear tube in a suitable fluid container.
  1. Remove and discard the blanking caps from the fuel filter fuel supply line and fuel filter.

  1. NOTE:
    NOTE:Make sure that the hand pressure pump arrow indicating the direction of fuel flow is pointing towards the fuel filter.
    Install the special tool between the fuel filter fuel supply line quick release coupling and the fuel filter union.

  1. Loosen the fuel filter bleed screw (special tool shown removed for clarity).

  1. Operate the hand pressure pump at least 30 times.

  1. CAUTION:
    CAUTION:Do not over tighten the fuel filter bleed screw. Failure to follow this instruction may result in damage to the fuel filter bleed screw and in turn result in air ingress to the fuel system.
    Tighten the fuel filter bleed screw finger tight (special tool shown removed for clarity).
  1. Remove the suitable fluid container.

  1. Remove the piece of clear tube (special tool shown removed for clarity).
  1. CAUTION:
    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 it to idle until it reaches normal operating temperature.
  1. Stop the engine.

  1. Remove the special tool.

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

  1. Install the fuel filter crash protection top shield.

  1. Install the engine cover.
  1. 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 : Fuel pump fuel supply line retaining clips
  1. Detach the fuel pump fuel supply line retaining clips
    1. Detach the fuel pump fuel supply line.
    1. Remove the fuel pump fuel supply line from the PCV hose(s).

Item 2 : Positive crankcase ventilation (PCV) hose retaining clamp
  1. Using the special tool, disconnect the PCV hose.

Item 4 : PCV hose retaining clamp
  1. Using the special tool, disconnect the PCV hose.

Item 6 : Fuel rail high-pressure fuel supply line

CAUTION:
CAUTION:Make sure that the high-pressure fuel supply line remains in contact with the fuel pump and fuel rail until all unions have been detached and cleaned. Failure to follow this instruction may result in foreign material ingress to the fuel injection system
  1. Detach the unions. Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply line, fuel pump and the fuel rail prior to removing the fuel rail high-pressure fuel supply line.
  1. Remove the fuel rail high-pressure fuel supply line. Using the pneumatic vacuum gun, vacuum foreign material from the fuel pump and the fuel rail open threaded ports.
  1. Install clean blanking caps to the open threaded ports on the fuel pump and fuel rail.

Item 8 : Fuel injector high-pressure fuel supply lines

CAUTION:
CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel injector and the fuel rail until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign material ingress to the fuel injection system.
  1. Detach the unions. Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply line, the fuel injector and the fuel rail prior to removing the fuel injector high-pressure fuel supply lines.
  1. Remove the fuel injector high-pressure fuel supply lines. Using the pneumatic vacuum gun, vacuum foreign material from the fuel injector and the fuel rail open threaded ports.
  1. Install clean blanking caps to the open threaded ports on the fuel injectors and fuel rail.

Installation Details

Item 9 : Fuel rail retaining bolts
  1. NOTE:
    NOTE:Do not tighten the fuel rail retaining bolts at this stage.
    Install the fuel rail retaining bolts finger tight.

Item 8 : Fuel injector high-pressure fuel supply lines
  1. CAUTION:
    CAUTION:Remove the blanking caps from the high-pressure fuel supply lines, fuel rail and fuel injectors at the last possible moment. Failure to follow this instruction may result in foreign material ingress to the fuel injection system.
    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 material to enter the fuel injection system.
    NOTE:
    NOTE:To aid installation of the high-pressure fuel supply line, the unions at the fuel rail end are colored gold.
    NOTE:
    NOTE:Install new fuel injector high-pressure fuel supply lines.
    NOTE:
    NOTE:Do not tighten the fuel injector high-pressure fuel supply line unions at this stage.
    Install the fuel injector high-pressure fuel supply lines in the sequence shown.
    • Remove and discard the blanking caps.
    • install the unions finger tight.

Item 6 : Fuel rail high-pressure fuel supply line
  1. Detach the fuel pump support bracket and position it to one side

  1. CAUTION:
    CAUTION:Remove the blanking caps from the high-pressure fuel supply lines, the fuel rail and fuel pump at the last possible moment. Failure to follow this instruction may result in foreign material ingress to the fuel injection system.
    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 material to enter the fuel injection system.
    NOTE:
    NOTE:Install new fuel rail high-pressure fuel supply line.
    NOTE:
    NOTE:Do not tighten the fuel rail high-pressure fuel supply line unions at this stage.
    Install the fuel rail high-pressure fuel supply line.
    • Remove and discard the blanking caps.
    • install the unions finger tight.

  1. Tighten the fuel rail retaining bolts.

  1. Tighten the fuel injector and the fuel pump high-pressure fuel supply line unions in the sequence shown.

  1. Tighten the fuel rail high-pressure fuel supply line unions in the sequence shown.

  1. Attach the fuel pump support bracket.

Fuel Pump > < Fuel Injectors - VIN Plate Emission Level Code: S