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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-)

Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel - Fuel Pump Focus 2004.75 (07/2004-)
Removal and Installation

Special Tool(s)

Universal Flange Holding Wrench

205-072 (15-030 A)

Hand Pressure Pump with Adaptor Kit

310-110
General Equipment
Worldwide Diagnostic System (WDS)
Pneumatic vacuum gun
Fluid container
Piece of clear tube
Materials
Name
Specification
Adhesive - Loctite 243
WSK-M2G349-A7 
Silicone Sealant
WSE-M4G323-A4 
Gasket Eliminator Sealant
WSK-M2G348-A5 
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.
  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. Remove the timing belt.
    For additional information, refer to: Timing Belt (303-01G, In-vehicle Repair).
  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 control valve 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).

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

 
Item
Part Number
Description
1
-
Fuel metering valve valve electrical connector
2
-
Fuel pressure regulator electrical connector
3
-
Fuel pump fuel return line
See Removal Detail
See Installation Detail
4
-
Fuel pump fuel supply line
See Removal Detail
See Installation Detail
5
-
Fuel pump support bracket
6
-
High-pressure fuel supply line
See Removal Detail
See Installation Detail

 
Item
Part Number
Description
7
-
Fuel pump pulley retaining bolts
See Removal Detail
See Installation Detail
8
-
Fuel pump pulley
See Removal Detail
See Installation Detail
9
-
Fuel pump sprocket seal retaining nuts
See Installation Detail
10
-
Fuel pump sprocket seal
See Removal Detail
See Installation Detail
11
-
Fuel pump sprocket retaining bolts
12
-
Fuel pump retaining bolts
See Removal Detail
See Installation Detail
13
-
Fuel pump
See Installation Detail
14
-
Fuel pump gasket
See Removal Detail
See Installation Detail
15
-
Fuel pump flange retaining nut
See Removal Detail
See Installation Detail
16
-
Fuel pump flange
See Removal Detail
See Installation Detail

6. To install, reverse the removal procedure.

  1. Carry out the fuel metering valve reset procedure by following the variable control valve (VCV) 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 3 : Fuel pump fuel return line

  1. Disconnect the fuel pump fuel return line.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
    • Install a clean blanking cap to the fuel pump fuel return line.
  1. Using the pneumatic vacuum gun, vacuum foreign material from the fuel pump open port.
  1. Install a clean blanking cap to the fuel pump.

Item 4 : Fuel pump fuel supply line
  1. CAUTION:
    CAUTION:Check the fuel pump fuel supply line O-ring seal for damage when removing the fuel supply line. If the O-ring seal is damaged, install a new O-ring seal. Failure to follow this instruction may result in foreign material ingress to the fuel injection system or fuel leakage.
    Disconnect the fuel pump fuel supply line.
    1. Release the locking clamp by pushing the two locking arms up.
    1. Gently pull the fuel pump fuel supply line from the fuel pump.
  1. Using the pneumatic vacuum gun, vacuum foreign material from the fuel pump open port.
  1. Install clean blanking caps to the fuel pump fuel supply line and the fuel pump.

Item 6 : 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. 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 fuel pump and the fuel rail.

Item 7 : Fuel pump pulley retaining bolts

  1. The fuel pump pulley is sealed to the fuel pump sprocket and the fuel pump pulley retaining bolts will require thorough cleaning before installation.

Item 8 : Fuel pump pulley

  1. The fuel pump pulley is sealed to the fuel pump sprocket and will require thorough cleaning before installation.

Item 10 : Fuel pump sprocket seal

  1. Discard the fuel pump sprocket seal.

Item 12 : Fuel pump retaining bolts
  1. NOTE:
    NOTE:The fuel pump retaining bolts cannot be removed completely.
    Access the fuel pump retaining bolts through the holes provided.

Item 14 : Fuel pump gasket

  1. Discard the fuel pump gasket.

Item 15 : Fuel pump flange retaining nut
  1. Using the special tool, hold the fuel pump flange and remove the fuel pump flange retaining nut.

Item 16 : Fuel pump flange
  1. Remove the fuel pump flange from the fuel pump driveshaft.

Installation Details

Item 16 : Fuel pump flange
  1. Install the fuel pump flange to the fuel pump driveshaft.

Item 15 : Fuel pump flange retaining nut
  1. Using the special tool, hold the fuel pump flange and tighten the fuel pump flange retaining nut.

Item 14 : Fuel pump gasket

  1. Install a new fuel pump gasket.

Item 13 : Fuel pump

  1. With the aid of another technician, support the fuel pump to assist the installation of the fuel pump retaining bolts.

Item 12 : Fuel pump retaining bolts
  1. Using adhesive, apply a thin bead of adhesive to the fuel pump retaining bolt holes.
  1. Tighten the bolts evenly, in order to pull the fuel pump squarely into position.

Item 10 : Fuel pump sprocket seal

  1. Install a new fuel pump sprocket seal.

Item 9 : Fuel pump sprocket seal retaining nuts
  1. Tighten the nuts in the sequence shown.

Item 8 : Fuel pump pulley
  1. Using sealant, seal the fuel pump pulley to the fuel pump sprocket.

Item 7 : Fuel pump pulley retaining bolts
  1. Using sealant, apply a thin bead of sealer to the outer edge of the fuel pump pulley retaining bolt holes.

Item 6 : High-pressure fuel supply line

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 to enter the fuel injection system.
CAUTION:
CAUTION:Remove the blanking caps from the high-pressure fuel supply line, the fuel pump and the fuel rail at the last possible moment. Failure to follow this instruction may result in foreign material ingress to the fuel injection system.
NOTE:
NOTE:Do not tighten the high-pressure fuel supply line unions until both unions are installed.
NOTE:
NOTE:Maintain pressure on the high-pressure fuel supply line to keep the line in contact with the fuel pump and the fuel rail cones while installing the unions.
  1. Remove and discard the blanking caps.

Item 4 : Fuel pump fuel supply line

  1. Remove and discard the blanking caps.

Item 3 : Fuel pump fuel return line

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

Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel > < Fuel Injection Supply Manifold - VIN Plate Emission Level Code: S