I have just replaced injector seals on my 53 fusion, after packing up on new years day. I had neglected to sort the problem and as a result damaged the injector wiring, fuel runoff pipes, covering everything in a hard carbon build up and making the repair extremely difficult.Do not leave it but sort it out asp.Ford dealer quote of £400.00 was a shock, the parts cost very little just four small copper washers and plastic spacers?. I did the job myself but it was very difficult to do.
Empty the radiator disconnect and remove the expansion tank, undo and remove the top cam belt cover, take of the air filter, the resonator from the turbo and undo the E G R tube at the camshaft cover left hand side. undo the two bolts from the front of the lower air filter cover and undo its two bolts at back of the cylinder head also undo the bolt of the E G R tube at the same time, loosen or remove the two bolts from the E G R vacuum unit located to the rear lower right of the cylinder head. After first disconnecting and removing the fuel filter. Move the fuel priming pump to one side there is a small manifold behind the bulb,this will move out of the way undo any electrical plugs at the same time, the large round plug behind the fuel fillter requires the gray tag to be lifted before pulling the plug out. Lift the combined plastic lower air filter cover and combined inlet manifold away, recover the four rubber seals. You are now looking at the injector tops.
Wow!
Carefully undo the the injector wiring plugs, the fuel run rubber tubes (it is wise to replace these with new, they will blow out later and cover the car in diesel very quickly, cost of new tubes £20.00). Undo the high pressure fuel inlet unions (use two spanners, do not move the the threaded part). undo the one bolt to each injector clamp and carefully lift the clamp with the injector out. Do not clean the injectors or try to dismantle them, A quick wipe with a cloth may be O K, do not touch or damage the nozzle end.
Remove the old plastic seal and recover the copper seals at the bottom of the injector tubes. (tip, use a length of flexible plastic tube, About 12mm taper it with knife or sandpaper and stick it into the hole at the bottom of the tubes, this will stop dirt falling into the cylinders. Replace the copper washer and the plastic seals with new and re-assemble in reverse to the above. use a torque wrench on every thing important.
As you can see it is not an easy feat and is made more complicated by the lack of space.
I am not a trained mechanic but I am competent enough to do this job. but it hurts and I am not impressed with the technology used by Ford on this engine. A diesel should be heavy, noisy, and tough not a lightweight alluminium unit that is pressurized to overcome emissions. I will be going back to petrol asp. Not impressed.
paul s
January 2009
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