Fuel injectors - removal and refitting
Caution: Refer to the precautions in Section 1 before proceeding.
Note: A tachometer and an exhaust gas analyser will be required to check the idle mixture on completion. New seals and retaining clips must be used when refitting the injectors, and special grease will be required - see relevant paragraph. If the injectors are thought to be faulty, it may be worth trying the effect of a fuel injector cleaning agent before removing them.
2.0 litre SOHC models
1 Disconnect the battery negative lead.
2 Disconnect the crankcase ventilation hose from the air inlet hose, then disconnect the air inlet hose from the inlet manifold and the airflow meter.
3 Disconnect the HT lead from the coil, then remove the distributor cap and position the cap and HT leads clear of the fuel rail assembly.
4 Disconnect the wiring plugs from the idle speed control valve, the throttle position sensor and the engine coolant temperature sensor.
5 Remove the fuel pressure regulator.
6 Unscrew the securing bolt and remove the throttle return spring bracket. Disconnect the throttle return spring.
7 Disconnect the fuel supply hose from the fuel rail. Be prepared for petrol spillage.
8 Disconnect the wiring plugs from the fuel injectors, noting their locations for use when refitting.
9 Remove the three securing bolts and withdraw the fuel rail and fuel injectors from the inlet manifold as an assembly (see illustrations).
18.9a Fuel rail front securing bolt (arrowed) . . .
18.9b . . . and rear securing bolts
10 To remove a fuel injector from the fuel rail, remove the retaining clip and withdraw the injector (see illustration).
18.10 Fuel injector retaining clip (A)
11 Overhaul of the fuel injectors is not possible, as no spares are available. If faulty, an injector must be renewed.
12 Commence refitting by fitting new seals to both ends of each fuel injector. Even if only one injector has been removed, new seals must be fitted to all four injectors (see illustration). Coat the seals with silicone grease to Ford specification ESEM - ICI71 A.
Similarly, renew all four fuel injector retaining clips.
18.12 Fuel injector with seals removed
13 Further refitting is a reversal of removal, ensuring that all hoses, wiring plugs and leads are correctly connected. When reconnecting the air inlet hose, make sure that the hose clips are correctly aligned - see illustration, Section 15.
14 On completion, check and if necessary adjust the idle mixture.
2.0 litre DOHC models
15 Disconnect the battery negative lead.
16 If desired, to improve access, disconnect the wiring from the inlet air temperature sensor in the inlet manifold. Similarly, the throttle cable can be moved to one side by disconnecting the cable from the throttle linkage. The spark plug HT leads can be disconnected and moved to one side, noting their locations and routing to aid refitting.
17 Slowly loosen the fuel rail fuel feed union to relieve the pressure in the system. Be prepared for fuel spillage, and take adequate fire precautions.
18 Disconnect the fuel feed hose from the fuel rail (see illustration).
18.18 Disconnecting the fuel feed hose from the fuel rail
19 Disconnect the fuel return hose from the fuel pressure regulator. Again, be prepared for fuel spillage.
20 Disconnect the vacuum pipe from the top of the fuel pressure regulator.
21 Disconnect the wiring plugs from the fuel temperature sensor and the fuel injectors, noting their locations to assist with refitting.
22 Unscrew the two securing bolts, and withdraw the fuel rail.
23 Lift the fuel injectors from their locations in the cylinder head (see illustration).
18.23 Lifting a fuel injector from the cylinder head
24 Overhaul of the fuel injectors is not possible, as no spares are available. If faulty, an injector must be renewed (refer to the note at the start of this procedure before condemning an injector).
25 Commence refitting by fitting new seals to both ends of each fuel injector. It is advisable to fit new seals to all the injectors, even if only one has been removed. Lubricate the seals with clean engine oil.
26 Further refitting is a reversal of removal, ensuring that all hoses, pipes and wiring plugs are correctly connected.
27 On completion, where applicable, check and if necessary adjust the idle mixture.
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