Chapter 1 Routine maintenance and servicing

Fuel system - electronic fuel injection engines 4C•58 Fuel tank - removal,inspection and refitting 3Proceed as described in Part A, Section 8,but before disconnecting the battery, relievethe residual pressure in the fuel system (seeSection 2), and equalise tank pressure byremoving the fuel filler cap.9 Fuel pump/fuel gaugesender unit - removal andrefitting3Refer to Part B, Section 9.10 Fuel tank ventilation tube -removal and refitting 3Refer to Part A, Section 10, but note that onmodels with evaporative emission control, theventilation tube connects to the combinedroll-over/anti-trickle-fill valve assembly but,instead of venting to atmosphere, a furthertube runs the length of the vehicle to a carboncanister in the front right-hand corner of theengine compartment.Further information on the evaporativeemission control system is contained in Part Eof this Chapter.14.7 Throttle housing retaining boltlocations (arrowed)11 Fuel tank filler pipe -removal and refitting 3Refer to Part A, Section 11.12 Fuel cut-off switch -removal and refitting 1Refer to Part B, Section 12.13 Fuel injection system -checking 3Refer to Part B, Section 1314 Fuel injection systemcomponents - removal andrefitting3Note: Refer to the warning note in Section 1before proceeding.Fuel rail and injectorsNote: For simplicity, and to ensure that thenecessary absolute cleanliness on reassembly,the following procedure describes the removalof the fuel rail assembly, complete with theinjectors and pressure regulator, so thatthe injectors can be serviced individually on a14.9a Disconnect the wiring multi-plugfrom each injector . . .clean work surface. It is also possible to removeand refit an individual injector, once the fuelsystem has been depressurised and the batteryhas been disconnected. If this approach isfollowed, read through the completeprocedure, and work as described in therelevant paragraphs, depending on the amountof preliminary dismantling required. Be carefulnot to allow any dirt to enter the system.1 Relieve the residual pressure in the fuelsystem (see Section 2), and equalise tankpressure by removing the fuel filler cap.Warning: This procedure willmerely relieve the increasedpressure necessary for the engineto run - remember that fuel willstill be present in the system components,and take precautions accordingly beforedisconnecting any of them.2 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1).3 Disconnect the HT lead connectors from thespark plugs, and release the leads from theirlocating grooves in the air inlet duct. Positionthem out of the way. On Turbo models, undo thetwo screws and remove the HT lead bracket.4 Remove the air inlet components asdescribed in Section 4.5 Unscrew the retaining nuts and the bolt,and detach the accelerator cable supportbracket at the throttle housing.6 Disconnect the wiring connector from thethrottle position sensor.7 Unscrew the four retaining bolts, andremove the throttle housing and its matingface gasket (see illustration).8 Disconnect the wiring multi-plug from theengine coolant temperature sensor and theinlet air temperature sensor.9 Disconnect the wiring multi-plugs from thefuel injectors, then undo the two retainingbolts and detach the wiring harness from thefuel rail (see illustrations).10 Unscrew the fuel supply pipe at the fuelrail. Plug the rail and pipe, to prevent furtherfuel spillage and the possible ingress of dirt.11 Disconnect the fuel return and vacuumpipes from the pressure regulator, and catchany fuel spillage in a clean cloth.12 Unscrew the fuel rail securing bolts, andcarefully withdraw the rail (complete withinjectors) from the engine (see illustrations).4C14.9b . . . unbolt the wiring harness . . .14.9c . . . and remove the completeharness14.12a Remove the fuel rail retainingbolts . . .1595Ford Fiesta Remake