303-04B Fuel Charging and Controls - 1.6L EcoBoost (132kW/180PS) - Sigma 2014 Fiesta
Removal and Installation Procedure revision date: 05/1/2013

Fuel Pump

Removal

WARNING: Do not work on the fuel system until the pressure has been released and the engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in serious personal injury.

WARNING: Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

NOTICE: Do not loosen any fittings or plugs on the fuel injection pump.

  1. Refer to: Fuel System Pressure Release (310-00B Fuel System - General Information - 1.6L EcoBoost (132kW/180PS) - Sigma, General Procedures).
  1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Refer to: Ignition Coil-On-Plug (303-07B Engine Ignition - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).
  1. Refer to: Air Cleaner Outlet Pipe (303-12B Intake Air Distribution and Filtering - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).
    1. Refer to: Quick Release Coupling (310-00B Fuel System - General Information - 1.6L EcoBoost (132kW/180PS) - Sigma, General Procedures).
  1. NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.

    1. Refer to: Spring Lock Couplings (310-00B Fuel System - General Information - 1.6L EcoBoost (132kW/180PS) - Sigma, General Procedures).
  1. NOTICE: To release the fuel pressure in the high pressure fuel tube, wrap the fuel injection pump flare nut with a shop towel to absorb any residual fuel pressure during the loosening of fuel injection pump flare nut.

  1. NOTE: Alternately loosen the 2 fuel injection pump bolts one complete revolution at a time.

Installation

  1. If any flat spots or scoring are found, especially in the indicated areas, then inspect the fuel injection pump and the fuel injection pump tappet drive lobe. Install new components as necessary.
  1. NOTICE: Only rotate the crankshaft Clockwise (CW) or damage to the engine may occur.

    NOTE: The cam lobe for the fuel injection pump must be at BDC for the fuel injection pump installation.

  1. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
  1. NOTE: Install a new fuel injection pump O-ring seal.

    Install the fuel injection pump and loosely install the 2 fuel injection pump bolts, alternately tighten each bolt one half of a revolution until seated.
    Torque : 13 Nm
  1. Torque : 3 Nm
  1. NOTE: Only tighten the 2 high pressure fuel tube flare nuts finger tight at this stage.

    NOTE: Make sure that a new component is installed.

    NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas.

    Torque :
      Stage 1:  21 Nm
      Stage 2:  Wait 5min
      Stage 3:  21 Nm
  1. NOTE: Only tighten the fuel supply tube flare nut and fuel supply tube studbolt finger tight at this stage.

    1. NOTE: Make sure that a new component is installed.

    1. Torque : 7 Nm
    1. NOTE: Calculate the correct torque wrench setting for the following torque. Refer to the Torque Wrench Adapter Formulas.

      Torque :
        Stage 1:  21 Nm
        Stage 2:  Wait 5min
        Stage 3:  21 Nm
    1. Refer to: Spring Lock Couplings (310-00B Fuel System - General Information - 1.6L EcoBoost (132kW/180PS) - Sigma, General Procedures).
    1. Torque : 10 Nm
    1. Torque : 6 Nm
  1. NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.

    1. Refer to: Quick Release Coupling (310-00B Fuel System - General Information - 1.6L EcoBoost (132kW/180PS) - Sigma, General Procedures).
    1. Torque : 5 Nm
  1. Refer to: Air Cleaner Outlet Pipe (303-12B Intake Air Distribution and Filtering - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).
  1. Refer to: Ignition Coil-On-Plug (303-07B Engine Ignition - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).
  1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Refer to: Fuel System Pressure Release (310-00B Fuel System - General Information - 1.6L EcoBoost (132kW/180PS) - Sigma, General Procedures).