Injectors — removal, inspection and installation (Escort 4)

Nozzle

Checking on the engine

To determine a faulty injector, you must:

• make sure the engine is in good condition and the compression level is the same in all cylinders;
• start the engine and warm it up to operating temperature;
• loosen the fuel line nipple nut on the injector being tested. Note whether the engine speed has changed. Perform the same test at fast idle;
• if the injector is in good working order, there will be a clear decrease in engine speed, accompanied by uneven operation. If the injector being tested is faulty, the change in engine speed will be insignificant and the extraneous knocking will disappear if it was present before.

Removal

Caution! The generator must be protected from diesel fuel.

1. Disconnect the ground wire from the battery.

2. Clean the high-pressure fuel lines, unscrew the union nuts on the fuel pump and protect them from contamination.

3. Carefully disconnect the injection line connections from the fuel pump.



4. Carefully disconnect the injection pipe connections from the injectors.

5. Disconnect the fuel return lines from the injectors.



6. Unscrew the nozzles and install protective caps on the sprayers.

7. Remove the thermal insulation washers and wipe them dry.

8. Clamp the sprayer body in a vice with soft jaws, disassemble the nozzle and, using a wooden tool, clean all the nozzle parts.

9. The nozzle needle, under its own weight, should slide tightly in the nozzle socket.

Installation

1. Install new thermal insulation washers with the convex side facing the cylinder head.

2. Insert the injectors into the holes in the cylinder head and tighten them to the required torque. It is permissible to use the injectors if after their disassembly, cleaning and subsequent assembly they restore their functionality and pass all tests.

3. Screw the injection pipe connections to the injectors. Make sure that the pipe mounting brackets (anti-vibration) are in the correct places.

4. Screw the injection pipe connections to the fuel pump.

5. Install fuel return lines on the injectors.

6. Connect the battery, start the engine and check the tightness of the connections (see subsection 3.2.4.3).