DIY nozzle repair ford kuga diesel

In detail: do-it-yourself repair of Ford Kuga diesel injectors from a real master for the site my.housecope.com.

The injectors in this system are controlled by an electronic control unit using a piezoelectric element or a magnetic solenoid. Thus, they are divided into electromagnetic and piezoelectric. Modern injector mechanisms use six to nine fuel injection phases. Almost all diesel vehicles today are equipped with this system.

The advantages of Common Rail over classic diesels are that the function of creating high fuel pressure and its injection into the cylinder are separate. This made it possible to smoothly regulate the pressure, volume and moment of injection, which led to an increase in engine power, a decrease in the amount of exhaust gases, a compact system, a decrease in noise and an economical fuel consumption (up to 20%).

The most common causes of Common Rail diesel injection malfunctions can be the wear of the moving parts of the diesel injection elements (high pressure fuel pumps, fuel injectors, fuel pumps) due to long-term operation or their premature wear when refueling and running the engine on low-quality fuel.

21 Feb 2017 The experience of operating diesel cars Ford Kuga shows that beliefs about the key value of injectors in cars are slightly exaggerated. On the other hand, many motor malfunctions are associated precisely with the contamination of this unit. But this does not mean that contamination of the injectors is the only possible malfunction. Problems often arise from loss of compression and failure of glow plugs. But below in the article, we will focus on the nozzles - the features of their work and the principles of replacement.

In case of correct operation, the injector ensures that there are no malfunctions in the functioning of the engine, reduced fuel consumption, no problems with dynamics, maintaining a safe temperature regime, and so on. As a rule, owners of diesel variants of Ford Kuga begin their inspection in winter, when the issue of high-quality cranking in difficult conditions is most important.

So, the diesel mixture ignites when the temperature reaches 350-400 degrees Celsius. If the engine is worn out, and the injector does not fulfill the task assigned to it (that is, it does not provide normal air atomization), then the diesel engine will not start.

Video (click to play).

For this reason, the manufacturer recommends replacing the nozzles every 60,000 kilometers, while the "native" parts are capable of moving at least 200-300 thousand kilometers. If necessary, then periodically it is worth removing the nozzles for inspections. In this case, the cleaning of devices should be carried out on special stands and using a specialized tool. It is forbidden to use various "fumki", sealants and other products, because the fuel mixture will still leak.

But here there is another obstacle, in order to check or replace the injectors on the Ford Kuga, they will have to be removed. And here already beginners may have a number of unforeseen problems. To avoid complications, below we will consider a detailed technique for dismantling the injectors.

To dismantle the injectors, proceed as follows:

Dismantle the intake pipe then lower the eight fuel injector cap nuts. At the end of this manipulation, dismantle the tubes by freeing them from the clips. In order to prevent accidental scrolling of the injectors when loosening the nuts, support the injectors with a regular wrench. At the same time, be careful - it is important to avoid getting dirt into the system;

Dismantle the injector return line by separating it from each individual node. Then unscrew a pair of bolts holding the nozzles and remove the products;

Remove the seal rings and injector guides then install new rings for sealing the injectors;

Mount the injectors and tighten the retaining bolts by hand. Then connect the return line to the injectors and install new fuel pipes. Place the new fuel pipes of the injectors here, securely fixing them in special clips. After that, pull the pipe union nuts by hand;

Stretch the injector mounting bolts. When doing this, follow the recommendations for broaching. According to the manufacturer, the force should be 4 N * m, after which the nuts reach another 45 degrees;

Stretch the flare nuts securing the fuel lines to the injectors. Here the moment should be 19 N * m, and in the second stage the force should be 30 N * m. In order to exclude the scrolling of the nozzles, it is worth using an open-end wrench;

Remove air from the system , which supplies fuel, and then put the intake pipe in place.

When removing injectors on Ford Kuga cars with a Euro-5 engine, the procedure should be as follows:

Discard the "negative" conductor from the voltage source in the car;

Remove the front cowl grille;

Twist a couple of bolts and disconnect the container with the brake compound from the panel. Then unscrew the five screws and dismantle the panel in the direction of the arrow;

Dismantle the top cover on the motor;

Loosen the clamps and remove the tube. Then unscrew the three mounting bolts (those that hold the casing) and remove it from the four retaining clips (located at the back). Next, dismantle the casing itself;

Slip on four union nuts (hold the tubes on the nozzles), then unscrew two pairs of union nuts. The latter attach the fuel pipes to the distribution line. After dismantling the pipes, it is forbidden to reuse them - throw away the products and install new ones;

Separate the electrical wiring connectors. This must be done on each of the nozzles. At the same time, separate the connector of the pressure sensor in the fuel supply line. Release the wiring from the three clips and remove it so it does not get in the way;

Discard the air tubes (fixed in five places) and dismantle all hoses (there are four of them);

Loosen the bolts and remove the injector retainers. Next, remove the devices themselves and the sealing rings;

Replace with new guides and O-rings. Perform further work in reverse order. Use new fuel pipes. During installation, first pull by hand, then with the right moment. This option avoids accidental misalignment or incorrect installation.

Removing injectors from a Ford Kuga for repair or subsequent cleaning is not an easy job. It requires a certain amount of attention, experience, knowledge of the sequence of actions and the availability of parts on hand for replacement. If any of the above components is missing, then it is recommended to contact knowledgeable specialists.

Come to our service station. We know Ford cars, have been working with them for a long time, we have a wide selection of original spare parts for replacement. After removing the nozzles, our masters check them for serviceability and clean them using specialized equipment (if necessary). With us, you are always confident in your car and the maximum engine resource.

Ford Kuga 2.0 diesel, 2008 onwards, mileage of about 300,000 km, according to the client on the way, it smoothly lost its tega, then completely stalled. scrolling with a starter jumps from 7 to 22 MPa, the diesel particulate filter is removed, the timing has checked everything by the marks, the car is working on the air, poke in the right direction all ideas are over

Like

I do not like

Slaventiy74 24 Feb 2016

Deal with fuel pressure. Check (replace) the fuel filter. Check the fuel system for air leaks, the diesel engine does not like it, implant a piece of a transparent hose into the system and look for air bubbles.

and also check the pressure regulator - it is on the bottom of the pump. often sails

New pump and filter too

Like

I do not like

Slaventiy74 24 Feb 2016

Try to directly supply fuel to the injection pump, either with a flushing stand, or from a canister by gravity, and start.

For a start, I would even supply fuel directly to the injection pump. And so it seems that their hoses are already transparent (or I have come across such) - you can immediately see the air.

Like

I do not like

kulibin26 25 Feb 2016

Check the recirculation system. EGR valve.

I do not even understand the logic of actions, it seems that they themselves wrote in the first post that the problem is with pressure.

Quote: "the fuel pressure when scrolling with the starter jumps from 7 to 22 MPa“

And then the generally clogged exhaust?

Or is it a typo? Or mistrust of the scanner?

Then with an oscillator or a tester, what is the voltage on the pressure sensor when scrolling?

Post edited by Artur2 on: 25 February 2016 - 22:12

The pressure jumps are the consequences of the problem, not starting the engine, and not the cause

Post has been editedDimanD: 26 February 2016 - 06:35

Like

I do not like

Slaventiy74 26 Feb 2016

Like

I do not like

Slaventiy74 26 Feb 2016

And on "opokhmelka" when does it work, what pressure does it show?

When disassembling the engine, cracks were found in the cylinder head

Like

I do not like

juzik 09 Mar 2016

When disassembling the engine, cracks were found in the cylinder head

Why was the engine dismantled? Now you will collect it and it will not start anyway, because you have not established the true reason for not starting. Because you didn't even bother to check the compression before disassembling.

Disassembled precisely by the fact that they measured the compression

DimanD Then voice the compression figures.

Ford Kuga is a very large and efficient crossover, equipped with different engines with different fuel supply systems. Among all the engines of this model, the most demanded at the moment are diesel power units equipped with a Common Rail accumulative fuel supply system from Bosch. These motors boast a high level of performance, but at the same time, they require more careful maintenance, because their breakdown rate is higher than that of diesel units without CR, due to the huge pressure generated inside the nozzles (injectors).

The Ford company did not pay much attention to the development of its own fuel supply systems in diesel engines and was largely focused on the modernization and creation of gasoline engines, the result of their activities was the emergence of EcoBoost gasoline power units based on the developments of Ford and Mazda. In Kuga, diesel engines - Duratorq, are equipped with a Common Rail system from Bosch, yes, of course, these are the same power units that were developed by the Peugeot-Citroen company at one time.

A feature of the CR from Bosch is its high level of maintainability, for which many motorists around the world love it. At the same time, the level of breakdowns of this system is several times higher than from similar products Siemens and Denso. CR is a system where fuel is supplied from a common rail to the injectors, due to which it turns out to increase the pressure several times, and, accordingly, the performance of the engine. Such a system saves fuel, releases less harmful substances into the atmosphere and significantly reduces the noise level of the power unit.

This system is based on the following components

high pressure fuel pump (high pressure fuel pump);
metering valve;
pressure regulator;
fuel rail (fuel battery);
injectors for supplying fuel to the cylinders.

The fuel pump is the main part of the CR system, however it is not as susceptible to damage as the injectors.

The injector is a small in size and thin in structure part of the system, consisting of:

solenoid;
anchor;
ball;
hulls;
sprayer;
multiplier (needle).

The most problematic part of the nozzle is the multiplier and sprayer.

Bosch injectors can last approximately 160-180,000 km, but this would be possible if the roads around the world were ideal, and in our country, alas, there are very few ideal roads. That is why our car service advises all Ford Kuga owners to come to check the fuel system 1-2 times a year, which will protect against major breakdowns and expenses for major repairs.

In our car service, injectors are diagnosed using special bench equipment from Bosch, but before that, we perform such operations as:

partial disassembly of the motor for dismantling the injector;
dismantling of injectors;
visual inspection for integrity.

On the bench equipment, integrity and tightness checks are carried out, the injection pressure is measured.

The Bosch injector is not repaired if:

it is impossible to dismantle the plunger;
there is no replacement atomizer;
there are serious traces of corrosion and mechanical damage.

During the diagnosis of injectors, you may experience such malfunction symptoms as:

poor opening of the nozzle when fuel is supplied;
fuel leakage from the sprayer before the nozzle opened;
fuel leakage during fuel injection;
a decrease in the supply pressure after the start of this process.

In these cases, in order to save time, effort and money, the specialists of our car service recommend replacing the injectors with a Ford Kuga.

The causes of breakdowns in all Common Rail (CR) systems are the same and the Bosch system installed in the Kugu is no exception. So, there are only three main reasons for the appearance of breakdowns.

increase in engine power;
use of low-quality fuel;
constant driving on bad roads.

For the first time, CR was installed on a passenger car in 1997, when the pressure in the injectors was not more than 1500 bar, today's diesel units with CR became more efficient, which led to an increase in pressure up to 2400-2500 bar. Due to such a high pressure, a faster wear of the atomizer occurs, a worn-out atomizer often simply cannot deliver fuel, which leads to an even greater increase in pressure inside the nozzle, which leads to the deposition of dirt and the development of corrosion.

Most of the problems with engines are associated with the fuel system, and in it most of the problems are associated with the pump and injectors. The injectors are easier to replace, which will be cheaper than replacing the pump, but if the injectors are not replaced or repaired in time, the pump can also be damaged.

Signs of malfunctioning injectors in the Ford Kuga are

increase in fuel consumption by more than 10%;
decrease in traction force;
problems when starting the power unit;
overheating of the motor;
depressurization;
problems with pressure regulation;

Replacing the injector on a diesel engine with CR in our car service is standard and consists of the following stages:

diagnostics;
partial disassembly of the power plant;
dismantling the nozzle;
flushing the motor if there is a leak;
reassembling an already new nozzle;
diagnostics for the correctness of the replacement;
output of the injector operation to the factory settings set by the manufacturer of the power unit.

Last week I attended training at VDO (a manufacturer of injectors and pumps that everyone calls Siemens, although VDO is now owned by Continental). There I have heard a lot and seen enough about Siemens common rail (we will call it that).

The conclusions are:
the system is indecently reliable if you pour good fuel. The first ever VDO service center has not seen a single pump under repair, which has become unusable due to mileage. The main reason is pollution or water in the fuel.The Germans complain that there is no clear business for the repair of such systems, since they practically do not break.
There are parts in the pump. which are screwed on only once, and if they are in good working order, they cannot be unscrewed! Do not put your pumps in the hands of non-professionals, they will be more whole.

Regarding the injectors: they explained to us in an accessible way why piezo injectors are not repaired in conditions different from the factory ones. Starting next year, some injectors will have atomizer replacement repair technology, but not all. Everything above the atomizer CANNOT BE DISASSEMBLED, assembled just like these systems was impossible! Do not get fooled by proposals for repairs, this is wasted money.

Ford Kuga Club Russia
Crossover Owners Club Forum

#81 22 Feb 2016, 23:41

#82 23 Feb 2016, 00:02

Shar
This is how anyone.

That electromagnetic more weave nursing that piezo. Only electromagnetic ones are repaired, and piezo ones are disposable. But piezo is more reliable. But the piezo is not Euro-5 (on 136 engines), but would be Euro-5, then who knows how much they would leave. I think that the same hundred - one and a half, as well as electromagnetic.

But while communicating with the bustorgdetal, I heard not for the first time - they say you have valves for Euro-3 or Euro-5 forces. That is, it is possible that our forces can be made Euro-3, but I am not sure if this is for sure.

#83 23 Feb 2016, 00:47

Ivan knock
I mean that piezo is more accurately dosed, better spray, faster response, multiple injection during one cycle, etc.

#84 23 Feb 2016, 00:54

#85 23 Feb 2016, 01:18

Read this about power systems.

#86 23 Feb 2016, 01:24

#87 23 Feb 2016, 01:33

#88 23 Feb 2016, 01:44

not, of course, everything dies, but here the main thing is in what percentage
you go to the diesels ford, there polls 2000-2007 (delphi em) replacement of the current injectors, their repair and the rest of the smut with fuel, after which in 2008 - 2012 there are practically no global problems (simmens piezy) - small things with valves, etc.
fresh cars - again a delfay rake and again the same nozzle problems appeared.

at the same time, we compare the fleet of Ford diesel engines - the most massive sector is just diesel mondeofocus 08-12 years

#89 23 Feb 2016, 02:27

#90 23 Feb 2016, 04:33

#91 23 Feb 2016, 09:08

#92 23 Feb 2016, 12:29

#93 23 Feb 2016, 13:29

Do you have one on Kuga?
PySy. The pump in the photo is from Merin 2006-2008, it is clearly older than ours.

The Ford Kuga is equipped with 4-cylinder in-line diesel power units Duratorq TDCi with a volume of 2.0 liters and a power depending on the degree of boost: 136, 140 and 163 hp. Compared to the well-proven petrol versions of the car, the Ford Kuga diesel has a little more problems. Although these motors are considered quite reliable. For diesel versions, you need to pay more attention to the quality of the fuel and the maintenance of the diesel unit - injectors and fuel equipment.

The most common Ford Kuga diesel malfunctions are associated with air leaks in the fuel system at the intake. The reasons for airing the fuel mixture can be different - from leaks in the fuel lines to problems with the high pressure fuel pump. Usually the malfunction is not serious and can be easily repaired.

On older versions, sometimes there were problems with the DPF sensor. The modifications of the maximum power (163 hp) engine had turbocharger breakdowns with a mileage of about 40 thousand km due to mechanical damage to the turbine blade.

Read also: DIY diesel injector repair

Less common are problems with flywheel play and failure of the fuel level sensor in the tank.

These are the most common malfunctions found when operating diesel versions of the Ford Kuga. Others may arise, but they are no longer characteristic of these particular motors. If you suspect that the engine is not working correctly, it is recommended to contact the service center.

Diesel center BOSCH has been engaged in the maintenance and repair of diesel engines for over 16 years. The accumulated experience, professional skills, the use of appropriate diagnostic equipment allows you to quickly localize the cause of the malfunction and eliminate the problem in a short time. For repairs, original components and spare parts are used.

FLOW BETWEEN NOZZLE AND NOZZLE
moreover, the test at the stand keeps the pressure up to 300, you put it, you go again, breaks the gasket

Added after 1 day
ALL SUCH RESPONSIBLE.

A similar problem has emerged the other day. Ordered washers, let's see what happens.

Added after 3 days
People, the problem continues exactly as described by the other victims, flowing from under the fitting. The service was sentenced to replace the nozzle without even removing it. But there is no trust in them. And the replacement is not a pretty penny. Who faced this.

Added after 1 day
The problem is solved by knowledgeable specialists. First, the fitting was replaced - it flows. Then they replaced the nozzle body, leaving the giblets the same. All OK!

... Specify after what (or when) the problems started ?? What was breaking, or what was being repaired before this problem

1. Specify how many valves per cyl. ? I looked at these letters of the motor - this is how the 2kl options went. and 4 cl.

2. That is why I asked about the number of r / shafts. That I suspect a failure in the timing phases.
But on the 8-valve there it is difficult to make a mistake with the marks. And p / shaft monolithic with cams
And on a 16-valve - it's easy to make a mistake with the labels. And p / shafts there punching, with push-on cams

3. It is not about the number 19 itself.
With such compression (if the rings are worn out) it can start badly, but as it grabs, it will work with complete combustion of fuel. And if it does smoke, it’s the blue fume from the oil. And this fume will not go away with warming up.

Much worse. if such a figure 19 appears from a large clearance “piston bottom - block head”. This is either from a thick gasket, or from a bent connecting rod happens. Then do not wait for the complete combustion of the fuel, until the engine warms up to hot. Since the temperature of the charge in the compression TDC drops sharply.
And on a number of motors, the SWIRLING-DISPLACEMENT of the mixture charge in the combustion chamber sharply deteriorates, where the valve discs should adjoin the depressions on the piston (at TDC), as close as possible.

We received a Ford Kuga 2 car with a 1.6 EcoBoost engine with an error in the self-diagnosis system "lean mixture", and there was also a complaint about increased fuel consumption: 12.5 l / 100 km using the on-board computer. One of the reasons for these "troubles" is the carbonization of the nozzles of direct injection fuel injectors, which we will fight with through testing and subsequent cleaning nozzles Ford Kuga .

We proceed to disassembly, remove the wipers, the panel under them, the decorative cover.

Removes the air duct and thoroughly purge the engine from dust, sand and other debris.

We remove the soundproof linings, disconnect the injector control wiring, remove everything that interferes with access to the injectors. We also dismantle the high-pressure fuel pipe from the injection pump to the rail.

So we observe the fuel rail and proceed to removal.

This is what the dismantled ramp looks like.

Using a special puller, carefully remove the fuel injectors. The plastic part of the nozzles is very fragile; under lateral loads it can even break (but not necessary).

We observe carbon deposits on the tips of the sprayers.

We install injectors on the diagnostic stand.

Let's start testing. We observe a spray, this is at a pressure of 5 bar.

And here is the result - not too rosy.

We place the nozzles in the ultrasonic bath and proceed to ultrasonic cleaning of nozzles Ford Kuga without their activation, that is, we only clean the nozzles without affecting the internal parts, thus the performance of the nozzles will not be impaired.

After retesting, we observe the leveling of filling levels and an overall increase in debit.

We install the nozzles on the test bench for tightness.

We give a pressure of 180 bar and observe.

No droplets are observed, which is very good.

This is what a cleaned sprayer looks like.

With the help of special crimps, we install the repair kit on the injectors and proceed with the assembly.

After the work carried out, resetting adaptations and running 63 km, the on-board computer showed a fuel consumption of 8.5 l / 100 km, which is not bad at all.

Thus, thanks to testing and ultrasonic cleaning of Ford Kuga injectors we managed to achieve a decrease in fuel consumption from 12.5 to 8.5 liters per 100 km of run, that is, by almost 30%.

Advertisements:

“Sales from electric: XProg-m Updated. (build Peter) + Chinese update. We buy iProg USB and motoadapter. Info - iProg USB + motoadapter.
Sales from Vasilich: Calculators for iProgPro. Calculators for iProgUSB. STool - Odometer correction program.
Attention to all iProg USB owners, the update begins SUMMER 2018 ... April 29, 2016 at Ford, Mazda, Jaguar, Lincoln

Everything you want to know about Ford Fusion, but did not know where to ask

# 21 Post Sergeysp "15 Jan 2015, 17:31

# 22 Post faraks "15 Jan 2015, 17:32

# 23 Message Sergeysp "15 Jan 2015, 17:38

# 24 Message ANG »15 Jan 2015, 19:05

# 25 Message Sergeysp »15 Jan 2015, 21:46

# 26 Message faraks »15 Jan 2015, 21:47

# 27 Message timoha-07 »16 Jan 2015, 22:29

# 28 Message bda1 »02 Feb 2015, 15:09

# 29 Message * Casper * »02 Feb 2015, 15:14

# 30 Message faraks »02 Feb 2015, 18:18

the injectors were sent to the service for testing (at the stand) at idle, the injectors do not give out fuel at all, when the speed rises (the injection pump is fed more into the main line) they start to work, at high pressure they start working properly, the spraying is normal (almost like new ones spray). surprised at the service how your engine still started. at idle, the injection pump produces about 250 bar, and the injectors start to work only from 800 and above! (so they said in the service, and gave a printout of the results)