Chapter 1 Routine maintenance and servicing

Fuel system - sequential electronic fuel injection engines 4D•514.17a Unscrewing fuel rail mounting bolts(arrowed)14.17b Note nose seals (arrowed) betweenrail and intermediate flange14.18 Removing an injector from the fuelrail. Note the O-ring seals (arrowed)and gasket. Discard the gasket - this must berenewed whenever it is disturbed.7 Refit in the reverse order of removal. Checkthat the mating faces are clean, and fit a newgasket. Adjust the accelerator cable asdescribed in Section 5 on completion.Fuel rail and injectorsNote: The following procedure is applicablemainly to Zetec engines; specific informationfor the PTE engine was not available at thetime of writing. However, apart from minordifferences in component attachments, bothengine types are very similar in this area.8 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 theengine to run - remember thatfuel will still be present in the systemcomponents, and take precautionsaccordingly before disconnecting any ofthem.9 Disconnect the battery negative (earth) lead- see Chapter 5A, Section 1.10 Remove the air inlet components asdescribed in Section 4.11 Disconnect the accelerator cable from thethrottle linkage (see Section 5).12 Disconnect the throttle position sensormulti-plug.13 Remove the throttle housing mountingscrews, then detach the throttle housing and14.20 Fit new nose seals (arrowed) beforerefitting the fuel railgasket from the inlet manifold. Discard thegasket - this must be renewed whenever it isdisturbed.14 Detach the crankcase breather hose fromthe cylinder head cover, and the fuel pressureregulator vacuum hose from the inletmanifold.15 Releasing the wire clips, unplug the fourfuel injector multi-plugs and the inlet airtemperature sensor multi-plug.16 Refer to Section 3 and disconnect the fuelfeed and return lines at the quick-releasecouplings, then unclip the fuel hoses from theinlet manifold; use rag to soak up any spiltfuel. Note: Do not disturb the threadedcouplings at the fuel rail unions unlessabsolutely necessary; these are sealed at thefactory. The quick-release couplings willsuffice for all normal service operations.17 Unscrew the three bolts securing the fuelrail (see illustration). Withdraw the rail,carefully prising it out of the inlet manifold,and draining any remaining fuel into a suitableclean container. Note the seals between therail noses and the manifold; these must berenewed whenever the rail is removed (seeillustration).18 Clamping the rail carefully in a vice fittedwith soft jaws, unscrew the two bolts securingeach injector, and withdraw the injectors (seeillustration). Place each in a clean, clearlylabelledstorage container.19 If the injector(s) are being renewed,discard the old injector, the nose seal and theO-rings. If only the injector O-rings are being14.24 Fuel pressure regulator vacuumhose (A) and retaining bolts (B)renewed, and it is intended that the sameinjectors will be re-used, remove the old noseseal and O-rings, and discard them.20 Refitting is the reverse of the removalprocedure, noting the following points:a) Lubricate each nose seal and O-ring withclean engine oil on installation.b) Locate each injector carefully in the fuelrail recess, ensuring that the locating tabon the injector head fits into the slotprovided in the rail. Tighten the boltssecurely.c) Fit a new seal to each fuel rail nose, andensure that the seals are not displaced asthe rail is refitted (see illustration).Ensure that the fuel rail is settled fully inthe manifold before tightening the bolts.d) Ensure that the hoses and wiring arerouted correctly, and secured onreconnection by any clips or tiesprovided.e) Adjust the accelerator cable as describedin Section 5.f) On completion, switch the ignition on andoff five times, to activate the fuel pumpand pressurise the system, withoutcranking the engine. Check for signs offuel leaks around all disturbed unions andjoints before attempting to start theengine.Fuel pressure regulator21 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 theengine to run - remember thatfuel will still be present in the systemcomponents, and take precautionsaccordingly before disconnecting any ofthem.22 Disconnect the battery negative (earth)lead - see Chapter 5A, Section 1.23 Disconnect the vacuum hose from theregulator.24 Unscrew the two regulator retaining bolts(see illustration) then use a wad of clean ragto soak up any spilt fuel, and withdraw theregulator.4D1595Ford Fiesta Remake