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Fuel Injection Supply Manifold - VIN Plate Emission Level Code: S > < Fuel Injection Component Cleaning

Focus 2004.75 (07.2004-)

Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel - Fuel Injectors—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
Cooling hose clamp remover/installer
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. Disconnect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

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

 
Item
Part Number
Description
1
-
Fuel filter 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 fuel metering electrical connector
7
-
Fuel pressure regulator electrical connector
8
-
Fuel rail pressure (FRP) sensor electrical connector
9
-
Fuel temperature sensor electrical connector
10
-
Fuel charging wiring harness retaining clip
See Removal Detail
11
-
Fuel injector electrical connector(s)
12
-
Fuel charging wiring harness
See Removal Detail

 
Item
Part Number
Description
13
-
Fuel injector high-pressure fuel supply lines
See Removal Detail
See Installation Detail
14
-
Fuel injector retaining bracket bolts
See Removal Detail
See Installation Detail
15
-
Fuel injector fuel return line
See Removal Detail
See Installation Detail
16
-
Fuel injector retaining brackets
17
-
Fuel injectors
See Removal Detail
See Installation Detail
18
-
Fuel injector to cylinder head sealing washers
  1. To install, reverse the removal procedure.
  1. NOTE:
    NOTE:The knock sensor (KS) reset procedure should only be carried out if 4 new fuel injectors have been installed.
    Carry out the KS reset procedure by following the combustion noise sensor (CNS) reset procedure, using the following WDS menu options: ToolBox/Powertrain/Service Functions.
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 filter fuel supply line retaining clips
  1. Remove the fuel filter fuel supply line retaining clips
    1. Detach the fuel filter fuel supply line.
    1. Remove the fuel filter fuel supply line retaining clips from the PCV hose(s).

Item 2 : Positive crankcase ventilation (PCV) hose retaining clamp
  1. Using the cooling hose clamp remover/installer, disconnect the PCV hose.
    • Position it to one side.

Item 4 : PCV hose retaining clamp
  1. Using the cooling hose clamp remover/installer, disconnect the PCV hose.
    • Position it to one side.

Item 10 : Fuel charging wiring harness retaining clip
  1. Detach the fuel charging wiring harness retaining clip from the stud.

Item 12 : Fuel charging wiring harness

  1. Position the fuel charging wiring harness to one side.

Item 13 : 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.

Item 14 : Fuel injector retaining bracket bolts

NOTE:
NOTE:Discard the fuel injector retaining bracket bolts.

Item 15 : Fuel injector fuel return line
  1. Disconnect the fuel injector fuel return line from the fuel injector.
    1. Using a suitable screwdriver, remove the fuel injector fuel return line retaining clip.
    1. Disconnect the fuel injector fuel return line from the fuel injector.
    • Install a clean blanking cap to the fuel injector fuel return line port.
    • Discard the O-ring seal.

Item 17 : Fuel injectors

NOTE:
NOTE:To remove the fuel injector number 4, it maybe necessary to loosen the valve cover in order to remove the fuel injector from the cylinder head.
  1. Install clean blanking caps to the fuel injector nozzle(s).

Installation Details

Item 17 : Fuel injectors

NOTE:
NOTE:If the valve cover has been loosened during the removal of the fuel injector number 4, tighten the valve cover retaining bolts after the fuel injector has been installed.
  1. Remove and discard the blanking caps.

Item 15 : Fuel injector fuel return line

NOTE:
NOTE:Install new O-ring seals to the fuel injector fuel return line.
  1. CAUTION:
    CAUTION:Push the fuel injector fuel return line gently into the fuel injector. Failure to follow this instruction may result in damage to the fuel injector fuel return line O-ring seals.
    Install the fuel injector fuel return line.

  1. CAUTION:
    CAUTION:Do not distort the fuel injector fuel return line retaining clip when installing it to the fuel injector. Failure to follow this instruction may result in fuel leaks.
    NOTE:
    NOTE:Install new fuel injector fuel return line retaining clip(s).
    Install the fuel injector fuel return line retaining clip.
    1. Using a suitable pair of long nosed pliers, hold the retaining clip in the location hole in the fuel injector.
    1. Using a suitable screwdriver, lever the retaining clip forward until an audible click is heard.

Item 14 : Fuel injector retaining bracket bolts
  1. NOTE:
    NOTE:Install new fuel injector retaining bracket bolts.
    Install the fuel injector retaining bracket bolts.
    • Tighten the bolts in two stages.
    • Stage 1: 5 Nm
    • Stage 2: 90 degrees

Item 13 : Fuel injector high-pressure fuel supply lines
  1. NOTE:
    NOTE:Do not remove the fuel rail retaining bolts.
    Loosen the fuel rail retaining bolts.

  1. CAUTION:
    CAUTION:Remove the blanking caps from the high-pressure fuel supply lines, the fuel rail and the 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: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.

  1. Tighten the fuel rail retaining bolts.

  1. Tighten the fuel injector high-pressure fuel supply line unions to the fuel injector(s) in the sequence shown.

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

Fuel Injection Supply Manifold - VIN Plate Emission Level Code: S > < Fuel Injection Component Cleaning