Fuel injectors (1.8 l diesel) (Focus 1)

Removal

All cars

1.

WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working with or near fuel-related items. Highly flammable mixtures are always present in such situations and may ignite. Failure to follow these instructions may result in injury.

CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and with very small clearances. Therefore, it is especially important to maintain absolute cleanliness when working with these components. Always plug any open ports or lines.

Disconnect the ground cable from the battery. For additional information, refer to Section 414-01.

Cars with charge air cooler.

2. Remove the air deflector.

3. Disconnect the charge air cooler inlet pipe.

4. Disconnect the charge air cooler outlet pipe and disconnect the intake air temperature (IAT) sensor electrical connector.

5. Remove the charge air cooler.

All cars

6.

CAUTION: Protect the generator from contamination. Failure to follow this instruction may result in premature failure of the generator.

To prevent contamination of the generator, cover it with a lint-free material.

7. Disconnect the high pressure fuel lines.

8. Remove and discard the high pressure fuel lines as unnecessary.

9. Disconnect the fuel return lines from the injectors. Pull the fuel return lines to release them.

10. Remove the fuel injector clamp.

11. Remove the fuel injector.

1. Turn the nozzle to release it.
2. Pull the nozzle to remove it.

12. Remove and discard the copper heat shield as unnecessary.

Installation

All cars

1.

WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working with or near fuel-related items. Highly flammable mixtures are always present in such situations and may ignite. Failure to follow these instructions may result in injury.

CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and with very small clearances. Therefore, it is especially important to maintain absolute cleanliness when working with these components. Always plug any open ports or lines.

NOTE: The fuel return line nipple connections on the fuel injectors must be positioned toward the front of the vehicle.

NOTE: Install new copper heat shield washer(s).

Install the fuel injectors.

2. Install the fuel return lines.

CAUTION: Protect the generator from contamination. Failure to follow this instruction may result in premature failure of the generator.

To prevent contamination of the generator, cover it with a lint-free material.

4.

NOTE: Install new high pressure fuel lines.

Install high pressure fuel lines

5. Install the high pressure fuel lines and tighten them by hand.

6. Remove the lint-free material from the generator.

7. Turn the ignition switch to position III (engine cranking). Crank the engine until clean fuel comes out of the fuel line nipple.

8. Tighten the high pressure fuel lines.