| Removal and Installation 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 can ignite. Failure to follow these instructions may result in personal injury. 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 fit blanking plugs to any open orifices or lines. | | -
Disconnect the battery ground cable.
For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
| | | -
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).
| 3. Remove the components in the order indicated in the following illustration(s) and table(s). 2 - High-pressure fuel supply line to fuel injection pump unions 9 - High-pressure fuel supply line to fuel injection pump unions 4. To install, reverse the removal procedure. | | -
Using the special tool, prime the fuel injection pump until clean fuel is seen entering the vacuum pump reservoir. | | | -
Turn the ignition switch to position three (engine cranking). Crank the engine until clean fuel escapes from the high-pressure fuel supply line unions. | | | -
Tighten the high-pressure fuel supply line unions. | Removal Details Item 3 : High-pressure fuel supply lines NOTE:Discard the high-pressure fuel supply lines. Item 7 : Fuel injectors | | -
NOTE:Rotate the injector to aid removal. Discard the fuel injector copper heat shield washer. | Item 10 : High-pressure fuel supply lines NOTE:Discard the high-pressure fuel supply lines. Item 11 : Fuel injector clamp retaining bolts NOTE:Discard the fuel injector clamp retaining bolts. Item 13 : Fuel injectors | | -
NOTE:Rotate the injector to aid removal. Discard the fuel injector copper heat shield washer. | Installation Details Item 13 : Fuel injectors NOTE:Install new fuel injector copper heat shield washer. Item 11 : Fuel injector clamp retaining bolts | | -
NOTE:Install new fuel injector clamp retaining bolts. Install the fuel injector bolts. - Tighten the bolts in two stages.
| Item 10 : High-pressure fuel supply lines NOTE:Install new high-pressure fuel supply lines. Item 8 : High-pressure fuel supply line to fuel injector unions | | -
Do not tighten the high-pressure fuel supply line unions at this stage. | Item 7 : Fuel injectors NOTE:Install new fuel injector copper heat shield washer. Item 3 : High-pressure fuel supply lines NOTE:Install new high-pressure fuel supply lines. Item 1 : High-pressure fuel supply line to fuel injector unions | | -
Do not tighten the high-pressure fuel supply line unions at this stage. | | 
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