Fuel injectors (1.8 l diesel) (Power unit / Fuel supply / Ford Focus 1 1998-2004)

Withdrawal

All cars

1.

WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations, there are always highly flammable mixtures that can ignite. Failure to follow these instructions may result in injury.

CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and very close clearances. Therefore, it is especially important to observe absolute cleanliness when working with these elements. Always insert plugs into any open holes or lines.

Disconnect the ground wire from the battery. See Section 414-01 for more information.

Vehicles with an aftercooler.

2. Remove the air baffle.

3. Disconnect the charge air cooler inlet pipe.

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

5. Remove the charge air cooler.

All cars

6.

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

Cover the generator with lint-free material to prevent contamination.

7. Disconnect the high pressure fuel lines.

8. Remove and discard high pressure fuel lines.

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

10. Remove the fuel injector clip.

11. Remove the fuel injector.

1. Rotate the nozzle to release it.
2. Pull on the nozzle to remove it.

12. Remove and discard the copper heat shield washer.

Installation

All cars

1.

WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations, there are always highly flammable mixtures that can ignite. Failure to follow these instructions may result in injury.

CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and very close clearances. Therefore, it is especially important to observe absolute cleanliness when working with these elements. Always insert plugs into any open holes or lines.

NOTE: The fuel return nipple connections on the fuel injectors must be located towards the front of the vehicle.

NOTE: Install a new copper heat shield (washers).

Install fuel injectors.

2. Install fuel return lines.

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

Cover the generator with lint-free material to prevent contamination.

4.

NOTE: Install new high pressure fuel lines.

Install high pressure fuel lines

5. Install high pressure fuel lines and hand tighten.

6. Remove lint-free material from the generator.

7. Switch 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.