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Fuel Injectors - Vehicles Built From: 08-2006 1.8L Duratorq-TDCi (Lynx) Diesel (75 PS-90 PS-110 PS) > < Fuel Injectors - 1.8L Duratorq-TDDi (Lynx) Diesel

Transit.Tourneo Connect 2002.5 (06.2002-)

Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel - Fuel Injectors—1.8L Duratorq-TDCi (Lynx) Diesel Transit/Tourneo Connect 2002.5 (06/2002-)
Removal and Installation

Special Tool(s)

Remover/Installer, Hose Clamp

303-397 (24-003)
General Equipment
Worldwide Diagnostic System (WDS)
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: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 has reached ambient temperature or is below 30°C, whichever is greater. 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 this instruction 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. Using datalogger in WDS, check that the fuel pressure has dropped to zero and that the fuel temperature has either reached ambient temperature or is below 30°C, whichever is greater.
  1. Disconnect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Remove the charge air cooler.
    For additional information, refer to: Charge Air Cooler - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel (75 PS/90 PS) (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  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 injector electrical connectors with lint-free material to prevent contamination from the cleaning fluid.
    Clean the fuel injectors, high-pressure fuel supply lines and surrounding areas. For additional information, refer to Fuel Injection Component Cleaning in this Section.

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

 
Item
Part Number
Description
1
-
Camshaft position (CMP) sensor electrical connector
2
-
Positive crankcase ventilation (PCV) hose retaining clamp
3
-
PCV hose
4
-
PCV hose retaining clamp
5
-
PCV hose

 
Item
Part Number
Description
6
-
Fuel return line
See Removal Detail
7
-
Fuel injector electrical connector
8
-
High-pressure fuel supply line clamp
See Removal Detail
9
-
High-pressure fuel supply line to number four fuel injector union
See Removal Detail
10
-
High-pressure fuel supply line to fuel injection supply manifold union
See Removal Detail
11
-
Number four fuel injector, high-pressure fuel supply line
See Removal Detail
See Installation Detail
12
-
Number four fuel injector & fuel injection supply manifold blanking caps
See Installation Detail
13
-
Number four fuel injector clamp retaining bolt
See Removal Detail
See Installation Detail
14
-
Number four fuel injector retaining clamp
15
-
Number four fuel injector
See Removal Detail
See Installation Detail
16
-
Number four fuel injector sealing washer
See Removal Detail
See Installation Detail

7. To install, reverse the removal procedure.

  1. Using WDS, configure the fuel injector(s) to the PCM.

Removal Details

Item 6 : Fuel return line

  1. Install a blanking cap to the fuel injector fuel return line spigot.

Item 8 : High-pressure fuel supply line clamp
  1. Make a note of the orientation of the clamp to make sure it is positioned in exactly the same position when installed.

Item 9 : High-pressure fuel supply line to number four fuel injector union

CAUTION:
CAUTION:Make sure that the high-pressure fuel supply line remains in contact with the fuel injector until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
CAUTION:
CAUTION:Make sure that the tool used to loosen the high-pressure fuel supply line union is used at the top of the union as this is where there is most material. Failure to follow this instruction may result in damage to the union.

Item 10 : High-pressure fuel supply line to fuel injection supply manifold union

CAUTION:
CAUTION:Make sure that the high-pressure fuel supply line remains in contact with the fuel injector until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
CAUTION:
CAUTION:Make sure that the tool used to loosen the high-pressure fuel supply line union is used at the top of the union as this is where there is most material. Failure to follow this instruction may result in damage to the union.

Item 11 : Number four fuel injector, high-pressure fuel supply line

NOTE:
NOTE:Using the engine vacuum cleaner, vacuum foreign material from the high-pressure fuel supply line, the fuel injector and the fuel injection supply manifold.
  1. Install a blanking caps to the open threaded ports of the fuel injector and the fuel injection supply manifold.

Item 13 : Number four fuel injector clamp retaining bolt

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

Item 15 : Number four fuel injector

NOTE:
NOTE:Clean the area around the fuel injector. For additional information, refer to Fuel Injection Component Cleaning in this Section.

Item 16 : Number four fuel injector sealing washer

NOTE:
NOTE:Discard the fuel injector sealing washer.

Installation Details

Item 16 : Number four fuel injector sealing washer

NOTE:
NOTE:Install a new fuel injector sealing washer.
  1. Install the fuel injector sealing washer into the fuel injector recess in the cylinder head.

Item 15 : Number four fuel injector

NOTE:
NOTE:Remove and discard the fuel injector nozzle blanking plug.
  1. Record the identification code from the new fuel injector to upload into WDS during configuration (the graphic shows an example of the identification code only).

Item 13 : Number four fuel injector clamp retaining bolt

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

Item 12 : Number four fuel injector & fuel injection supply manifold blanking caps

CAUTION:
CAUTION:Remove the blanking plugs from 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.
  1. Remove and discard the blanking plugs.

Item 11 : Number four fuel injector, high-pressure fuel supply line

CAUTION:
CAUTION:Remove the blanking plugs from the high-pressure fuel supply line at the last possible moment. Failure to follow this instruction may result in foreign matter 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:Lubricate the high-pressure fuel supply line union threads with clean lubricant.
NOTE:
NOTE:To aid installation of the high-pressure fuel supply line, the union at the fuel injector end is etched with the cylinder number.
NOTE:
NOTE:Install a new high-pressure fuel supply line.
  1. Remove and discard the blanking plugs.

Fuel Injectors - Vehicles Built From: 08-2006 1.8L Duratorq-TDCi (Lynx) Diesel (75 PS-90 PS-110 PS) > < Fuel Injectors - 1.8L Duratorq-TDDi (Lynx) Diesel