Fuel Injection System - 6.9l Diesel Ford Cab & Chassis Ranger

COMPONENT TESTING

Note. Specific component testing information not available. Refer to any tests performed during TROUBLE SHOOTING or TESTING procedures.

DESCRIPTION

In this diesel system, a mechanical high pressure rotary pump is gear driven at camshaft speed. Through this method the pump injects a precisely metered amount of fuel into each cylinder at the proper time. The pump is mounted on top of the engine and provides necessary timing advance under all operating conditions.

Eight high pressure fuel pipes carry fuel from pump to an injection nozzle in each cylinder. All 8 pipes are the same length to ensure that there is no variance in timing. Engine RPM is controlled by a rotary fuel metering valve. As the accelerator pedal is pushed down, a throttle cable opens the metering valve and allows increased fuel delivery. A mechanical fuel pump located on the right side of the engine, draws fuel from the fuel tank and delivers it to the injection pump via a fuel filter.

The fuel filter is located between the mechanical pump and injection pump (mounted on side of engine block). Any excess fuel in the supply system is returned to the tank by a fuel return system. A water separator is located in the fuel line between the tank and the mechanical fuel pump. The separator collects water out of the fuel system. When the separator becomes about 1/3 full, a warning lamp on the dash will light up. When the warning lamp lights up, water should be drained from the separator. The warning lamp will also light when the key is in the "START" position to serve as a lamp test.

An electrical glow plug system is used to assist in engine starting and cold operation. A glow plug is located in the pre-chamber for each cylinder. Glow plug current is controlled by a temperature switch, a power relay and an after glow relay.

Stanadyne DB-2 Diesel Fuel Injection Pump Disassembly of pump should only be performed by an authorized calibration shop. Scheme 35

FUEL INJECTION PUMP

The Stanadyne DB-2 twin plunger mechanical injection pump contains a low pressure vane-type transfer pump, a high pressure distributor-type injection pump, a centrifugal governor and an injection timing advance mechanism.

The transfer pump output pressure (sometimes referred to as injection pump housing pressure) averages 50-100 psi (3.5-7.0 kg/cm 2 ) depending upon engine speed and application. The plunger injection pump boosts fuel pressure to about 2000 psi (140 kg/cm 2 ). The pump assembly is also equipped with an electric fuel shut-off valve.

Ford Diesel Fuel System Bleed air from system whenever fuel lines are opened. Scheme 36

INJECTORS

The injection nozzles spray fuel into a pre-chamber as each compression stroke occurs. Injector opening pressure is adjusted with a shim on top of the needle valve return spring. (Scheme 37) The injector receives a high pressure pulse of fuel which forces open the needle valve allowing the fuel to pass into the prechamber.

Ford Diesel Injector Injector must be free of dirt prior to reassembly. Scheme 37

FUEL SUPPLY SYSTEM

Diesel fuel is drawn through a water separator from the fuel tank by an engine mounted mechanical fuel pump. This pump is driven by an eccentric cam mounted on the crankshaft and puts out about 3 psi to the injection pump. A small screen type filter is located in the fuel tank at the pickup. Diesel fuel arrives at the center inlet fitting on the injection pump after leaving the filter. A fuel return line is provided to return any excess fuel to the tank.

FUEL INJECTION LINES

Eight high pressure fuel injection lines are routed from injection pump to an injector in each cylinder. The lines are of equal length but are bent differently to maintain equal length, prevent any difference in timing from cylinder-to-cylinder and aid installation. Lines are not interchangeable and are pre-bent by the manufacturer.

GLOW PLUG SYSTEM

Engine starting is aided by an automatic electric glow plug system. Function of this system is to pre-heat the combustion chamber to aid ignition of fuel.

System consists of eight glow plugs, control switch, power relay, "GLOW PLUG" lamp and a wiring harness which incorporates eight fusible wires (one for each glow plug) located between wiring harness and glow plug terminal.

Glow plugs are threaded into each cylinder combustion chamber. Glow plugs are small heaters that assist in cold starting. The glow plug controller and relay cycle 12 volts to these 6 volt heaters, which causes them to heat rapidly. After the engine starts, the glow plugs remain on between 4 and 10 seconds during initial starting cycle.

Before suspecting the fuel injection system as a possible source of engine trouble, other engine systems should be checked. The exhaust system should not be restricted, the fuel supply system should supply an adequate amount of clean fuel to the injection pump, and the air intake system should not be restricted. If after checking the other systems and making the necessary repairs a problem still exists, perform the following test

1. Check fuel lines to injectors for kinks or restrictions. Repair as necessary. Run engine at RPM where problem was most pronounced.
2. Momentarily loosen (1/2-1 turn) fuel line on 1 injector. Then tighten fuel line to specification. Repeat for each cylinder.
3. If 1 or more nozzles are found where loosening fuel line makes no difference in operation, that nozzle should be removed and tested.

GLOW PLUG SYSTEM TROUBLE SHOOTING

Note. Ford has updated it's Glow Plug Testing procedures please see TSB 88-11-19 in the TECHNICAL SERVICE BULLETIN section.

1. Connect a 12 volt test lamp between the glow plug power relay output and ground. Turn ignition on. Test lamp should light, stay lit for 4 to 10 seconds, then cycle on and off. If so, proceed to step 2. If test lamp does not light, perform «GLOW PLUG TEST C»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-test-c-test-lamp) . If test lamp stays on continuously, perform «GLOW PLUG TEST B»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-test-b-test-lamp) . If test lamp lights for 4-10 seconds and then goes out and stays out, perform GLOW PLUG TEST E.
2. With test lamp still connected, start engine. Test lamp should cycle on and off for as much as 2 minutes, then turn off. If so, perform «GLOW PLUG TEST A»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-test-a-test-lamp) . If test lamp continues to cycle on and off after 2 minutes, perform «GLOW PLUG TEST D»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-test-d-test-lamp) . If test lamp does not light, perform «GLOW PLUG TEST E»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-test-e-test-lamp) .

Engine Wiring System Diagram. Scheme 38

GLOW PLUG LAMP TROUBLE SHOOTING

1. Turn ignition on. Glow plug lamp should light for 4-10 seconds, depending on engine temperature, and then go out. If lamp lights for 4-10 seconds, glow plug lamp system is okay. Perform «GLOW PLUG SYSTEM TROUBLE SHOOTING»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-system-trouble-shooting) . If lamp does not light and engine is at or near operating temperature, allow engine to cool down and retest. If lamp still does not light, proceed to step 2.
2. Perform «GLOW PLUG TEST C»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-test-c-test-lamp) . If test lamp functions as required and glow plug lamp did not light in step 1, proceed to step 3. If test lamp does not function properly, fault is within glow plug system. Repeat «GLOW PLUG SYSTEM TROUBLE SHOOTING»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-system-trouble-shooting) procedure.
3. Remove bulb from "GLOW PLUG" indicator and check bulb. Replace as needed. If bulb is good, repair or replace chassis wiring as needed. Repeat «GLOW PLUG LAMP TROUBLE SHOOTING»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-lamp-trouble-shooting) .

1. Remove injection nozzles from engine. Test injectors using calibration fluid at room temperature. Bleed air out of tester by opening tester valve slightly and pumping handle several times. Close valve.
2. Install injection nozzle on tester. Open tester valve and pump tester handle quickly 8-10 times to bleed air from nozzle. Slowly lower tester handle and note pressure shown on gauge as injector nozzle opens. Repeat several times to obtain accurate reading.
3. Normal injection starting pressure should be 1800-1950 psi (126-137 kg/cm 2 ). If injection starting pressure is below 1425 psi (100 kg/cm 2 ), replace injector.
4. Using injector tester, maintain pressure at about 200 psi (14 kg/cm 2 ) below nozzle opening pressure. No fuel leakage should occur. Slight wetting of tip after 5 seconds is OK. DO NOT wipe tip of nozzle with fingers. If leakage does occur, injector must be replaced.
5. Operate tester using quick strokes while observing flow from injector return ports. A slight leak-off of 1 or 2 drops per stroke is normal. If a solid stream is expelled from return port, injector must be replaced.
6. Build up pressure in the injector tester to just below injection starting pressure. Quickly lower handle on tester and observe fuel spray pattern. Fuel should be uniformly atomized. Droplets or a solid stream of fuel indicates a faulty nozzle. (Scheme 39)

Injector Spray Patterns Injector must not drip when needle valve is closed. Scheme 39

TRANSFER PUMP (HOUSING) PRESSURE

Remove screw from transfer pressure port. (Scheme 40) Install a gauge adapter (T83T 9000 A or equivalent) into transfer pressure port. Connect a 0-150 psi (0-10.55 kg/cm 2 ) pressure gauge to adapter. Run engine at 3,300 RPM, under no load, with transmission in Neutral. Pressure should be 90-110 psi (6.3-7.7 kg/cm 2 ). If pressure is not to specifications, replace pump and retest. If performance problem still exists, check and adjust timing.

Transfer Pressure Test Connection. Scheme 40

Glow Plug System Test Connections. Scheme 41

GLOW PLUG TEST A TEST LAMP SIGNAL CORRECT

Note. Ford has updated it's Glow Plug Testing procedures please see TSB 88-11-19 in the TECHNICAL SERVICE BULLETIN Section.

1. Remove all leads from glow plugs. Connect a test lamp between glow plug power relay output and ground. Turn ignition on. Measure voltage at each glow plug lead whenever test lamp is lit. Voltage should be at least 11 volts. If voltage is ok at all leads, proceed to step 4. If voltage is not ok at 1 or more leads, proceed to step 2.
2. Turn ignition off. Disconnect fusible links from chassis harness and engine glow plug harness. Check continuity of fusible links with an ohmmeter. If 1 or both fusible links are open, replace fusible link and repeat step 1. If both fusible links are ok, proceed to step 3.
3. Turn ignition off. Disconnect engine harness from chassis connector and all glow plugs. Check resistance between chassis connector left and right bank glow plug terminals and each glow plug lead. If any resistance is 1 ohm or more, replace engine harness and recheck vehicle operation. If resistance is more than 1 ohm, proceed to step 4.
4. Turn ignition off. Remove test lamp from power relay. Check resistance between glow plug terminal and metal case of glow plug. If resistance is less than 2 ohms at all glow plugs, glow plug system is OK, problem is engine related. If resistance is more than 2 ohms at any glow plug(s), replace glow plug(s), reconnect harness and check vehicle operation.

GLOW PLUG TEST B TEST LAMP ON CONTINUOUSLY

Note. Ford has updated it's Glow Plug Testing procedures please see TSB 88-11-19 in the TECHNICAL SERVICE BULLETIN Section.

1. Disconnect all leads from glow plugs and do not reconnect until after system has been checked for proper operation. Connect a 12 volt test lamp to glow plug power relay output and ground. Turn ignition on, but do not start engine. If test lamp cycles but "GLOW PLUG" light in dash does not, repair or replace circuit wiring to light, or replace bulb, as needed. Repeat «GLOW PLUG SYSTEM TROUBLE SHOOTING»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-system-trouble-shooting) . If test lamp does not turn off, proceed to step 2.
2. With test lamp still connected, turn ignition on. Disconnect wiring harness from control switch. If test lamp goes out, replace control switch and repeat «GLOW PLUG SYSTEM TROUBLE SHOOTING»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-system-trouble-shooting) . If test lamp does not go out, proceed to step 3.
3. With test lamp still connected, turn ignition on. Disconnect engine harness from chassis harness. If test lamp goes out, replace engine harness and go to step 7. If lamp stays on, go to step 4.
4. Turn ignition off. Disconnect signal lead from power relay. Turn ignition on. If test lamp goes out, repair or replace chassis harness as needed and go to step 5. If lamp stays on, go to step 5.
5. Turn ignition off, remove test lamp and disconnect battery lead from power relay. Reconnect test lamp. With power relay output lead still connected, turn ignition on. If test lamp remains on, repair or replace chassis wiring harness to glow plugs. If lamp goes out, replace power relay.
6. With ignition off, remove test lamp from power relay and reconnect all leads (EXCEPT glow plugs). Check continuity from each glow plug lead to power relay output. If resistance is less than 1 ohm for all glow plugs, go to step 8. If resistance is 1 ohm or greater for 1 or more glow plugs, go to step 7.
7. With ignition off, disconnect engine harness and chassis harness fusible links from chassis harness. Check resistance of all fusible links. If resistance of all links is less than 1 ohm, replace engine harness. If resistance of one or more fusible link is 1 ohm or greater, replace link and repeat step 6.
8. With ignition off and engine harness disconnected at glow plugs, check resistance between each glow plug terminal and metal shell of glow plug. If resistance is less than 2 ohms for all plugs, glow plug system is OK. Reconnect engine harness to glow plugs and repeat «GLOW PLUG SYSTEM TROUBLE SHOOTING»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-system-trouble-shooting) . If resistance for any plug is 2 ohms or greater, replace glow plug(s). Reconnect engine harness to glow plugs and repeat «GLOW PLUG SYSTEM TROUBLE SHOOTING»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-system-trouble-shooting) .

GLOW PLUG TEST C TEST LAMP DOES NOT LIGHT

Note. Ford has updated it's Glow Plug Testing procedures please see TSB 88-11-19 in the TECHNICAL SERVICE BULLETIN Section.

1. Ensure that ignition has been off for at least 1 minute, then turn ignition on. If "GLOW PLUG" dash light comes on, perform «GLOW PLUG TEST E»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-test-e-test-lamp) . If not, for engine at normal operating temperature, condition is normal. For coolant temperatures below normal, turn ignition off, wait 2 minutes, and turn ignition back on. If light comes on, perform «GLOW PLUG TEST E»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-test-e-test-lamp) . If light does not come on, proceed to step 2.
2. Check batteries for sufficient charge. Batteries should be able to crank engine. If charge is ok, proceed to step 3. If charge is low, charge or replace batteries as necessary and repeat «GLOW PLUG SYSTEM TROUBLE SHOOTING»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-system-trouble-shooting) .
3. Turn ignition off. Wait at least 1 minute, then connect test lamp between power relay output and ground. Turn ignition on. If test lamp comes on but dash light does not, repeat «GLOW PLUG LAMP TROUBLE SHOOTING»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-lamp-trouble-shooting) , step 3. If test lamp does not light, proceed to step 4.
4. Check fusible link from ignition switch to control switch. If fusible link is ok, go to step 8. If fusible link is not ok, proceed to step 5.
5. Replace fusible link and repeat «GLOW PLUG SYSTEM TROUBLE SHOOTING»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-system-trouble-shooting) . If fuse blows, proceed to step 6. If fuse does not blow and system operates correctly, testing is complete. If fuse does not blow and system still does not operate correctly, go to step 8.
6. Remove signal lead from power relay. Replace fusible link. Turn ignition on and then off. If fuse blows, proceed to step 7. If fuse does not blow, replace power relay and repeat «GLOW PLUG SYSTEM TROUBLE SHOOTING»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-system-trouble-shooting) .
7. Disconnect chassis harness from engine harness. Replace fusible link. Turn ignition on and then off. If fuse blows, repair chassis wiring harness and repeat «GLOW PLUG SYSTEM TROUBLE SHOOTING»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-system-trouble-shooting) . If fuse does not blow, proceed to step 8.
8. Turn ignition off. Reconnect all leads (including power relay signal lead). Wait at least 1 minute and turn ignition back on. Check voltage between power relay signal lead and ground. If voltage is at least 11 volts, proceed to step 9. If less than 11 volts, go to step 10.
9. With ignition off, check voltage between power relay input terminal and ground. If voltage is at least 11 volts, check power relay ground connection or replace relay. If voltage is below 11 volts, charge or replace batteries and/or repair wiring from batteries to power relay. Repeat «GLOW PLUG SYSTEM TROUBLE SHOOTING»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-system-trouble-shooting) .
10. With ignition off, disconnect power relay signal lead and engine harness at control switch. Check resistance between control switch connector Pin No. 6 and power relay signal lead. If resistance is less than 1 ohm, go to step 12. If not, proceed to step 11.
11. With ignition off, disconnect chassis harness from engine harness. Disconnect power relay signal lead. Check resistance between chassis side wiring connector terminal No. 6 and power signal lead. If resistance is less than 1 ohm, replace engine harness. If not, repair or replace chassis wiring. Repeat «GLOW PLUG SYSTEM TROUBLE SHOOTING»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-system-trouble-shooting) .
12. Remove engine harness connector to control switch and turn ignition on. Check voltage between control switch connector Pin No. 3 and ground. If voltage is 11 volts or greater, replace glow plug control switch and repeat «GLOW PLUG SYSTEM TROUBLE SHOOTING»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-system-trouble-shooting) . If voltage is less than 11 volts, proceed to step 13.
13. Turn ignition off. Disconnect chassis harness from engine harness, Turn ignition back on. Check voltage at Pin No. 3 on chassis side of connector. If voltage is 11 volts or greater, replace engine harness. If not, repair or replace chassis wiring. Repeat «GLOW PLUG SYSTEM TROUBLE SHOOTING»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-system-trouble-shooting) .

GLOW PLUG TEST D TEST LAMP CYCLES CONTINUOUSLY

Note. Ford has updated it's Glow Plug Testing procedures please see TSB 88-11-19 in the TECHNICAL SERVICE BULLETIN Section.

Disconnect engine harness connector at control switch. Turn ignition on. Check voltage between control switch connector Pin No. 1 and ground. If voltage is 11 volts or more, turn ignition off and replace control switch. If not, turn ignition off and replace engine harness. Repeat GLOW PLUG SYSTEM TROUBLE SHOOTING and step 4 of GLOW PLUG TEST A .

GLOW PLUG TEST E TEST LAMP DOES NOT CYCLE

Note. Ford has updated it's Glow Plug Testing procedures please see TSB 88-11-19 in the TECHNICAL SERVICE BULLETIN Section.

1. Connect a test lamp between glow plug power relay output and ground. Turn ignition on, but do not start engine. If test lamp lights, proceed to step 2. If test lamp does not light, for coolant temperatures of 140° F (60° C) or above, condition is normal. For coolant temperatures below 140° F (60°C), turn ignition off, wait 5 minutes, and turn ignition back on. If lamp lights, proceed to step 2. If lamp does not light, perform GLOW PLUG TEST C.
2. Turn ignition off. Disconnect chassis harness from glow plug power relay. Disconnect engine harness from control switch and all glow plugs. Check resistance between control switch connector Pin 4 and glow plug relay power output. If resistance is less than 1 ohm, go to step 4. If resistance is 1 ohm or more, proceed to step 3.
3. Turn ignition off. Disconnect chassis harness from engine harness. Check resistance between chassis harness and glow plug power relay output. If resistance is less than 1 ohm, replace engine harness. If more than 1 ohm, replace fusible link(s) or repair chassis harness. Repeat «GLOW PLUG SYSTEM TROUBLE SHOOTING»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-system-trouble-shooting) .
4. With ignition off, check resistance between control switch connector Pin 5 and ground. If resistance is less than 1 ohm, proceed to step 5. If not, repair engine harness ground connection or replace harness. Repeat «GLOW PLUG SYSTEM TROUBLE SHOOTING»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-system-trouble-shooting) .
5. With ignition off, disconnect engine harness at control switch. Connect all other leads. Check resistance between control switch Pin 6 and ground. If resistance is 2.5 ohms or more, replace control switch. If not, replace power relay. Repeat «GLOW PLUG SYSTEM TROUBLE SHOOTING»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-system-trouble-shooting) and step 4 of «GLOW PLUG TEST A»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel__glow-plug-test-a-test-lamp) .

Removal

1. Open hood. Disconnect battery ground cables from both batteries. Remove engine oil filler neck. Remove bolts attaching injection pump to drive gear. Disconnect electrical connectors from injection pump. Disconnect accelerator cable and cruise control cable (if equipped) from throttle lever.
2. Remove air cleaner and cover air intake. Remove accelerator cable bracket, with cables attached, and position out of the way. On van models, remove fuel inlet and return lines from fuel filter. Remove filter bracket and filter as an assembly.
3. On all models, remove fuel line from injection pump inlet and cap fittings. Remove and cap injection pump inlet elbow and fitting adapter.
4. Remove fuel return line from injection pump, rotate out of the way and cap both fittings. If injector lines are to be removed, loosen line fittings at pump. Disconnect fuel lines from injection nozzles and cap line fittings and nozzles.
5. Remove 3 injection pump retaining nuts. If injection pump or fuel lines are to be replaced, remove injector lines from pump and cap all fittings. Injector lines must be removed in the following order: 5-6-4-8-3-1-7-2. (Scheme 42) Remove injection pump from engine compartment (through passenger compartment on van models).

Installation

To install, reverse removal procedure, noting the following

1. Use a new "O" ring on drive gear end of injection pump.
2. Install injector lines AFTER pump is installed. Lines must be installed in the following order: 2-7-1-3-8-4-6-5.
3. Use new "O" ring on injection pump fitting adapter.
4. Purge injector lines by loosening connector 1/2 to 1 turn and cranking engine until a solid stream of fuel flows from connector.
5. Check and adjust injection pump timing as necessary.

Injection Pump Line Sequence Remove and install injector lines in proper sequence. Scheme 42

1. Before removing nozzles, clean nozzle, surrounding area and piping connections with clean fuel or solvent to prevent contamination. Blow area dry with compressed air. Remove fuel line retaining clamps from lines being removed.
2. Disconnect nozzle fuel inlet and fuel return "T" fittings from each nozzle and position out of way. Cap all open connections. Unscrew nozzle and remove nozzle and copper washer from engine.
3. DO NOT strike nozzle tip against any hard surface during removal. Cap both ends of nozzle and store in a rack such that nozzles may be reinstalled in their original cylinders.

1. Clean nozzle bore in cylinder head thoroughly before reinstalling nozzle. Remove protective cap from nozzle tip. Coat nozzle threads with anti-seize compound. Install a new copper gasket on nozzle using a small amount of grease to retain gasket on nozzle.
2. Install nozzle into cylinder head bore and tighten. Remove caps from fuel lines and nozzle fittings. Install fuel inlet and return "T" fittings on nozzle. Install 2 new "O" rings on each "T" fitting. Connect fuel line to nozzle.
3. Install fuel line retainer clamps and tighten. Purge injector lines if needed by loosening connector 1/2 to 1 turn and cranking engine until a solid stream of fuel flows from connector. Run engine and check for fuel line leakage.

Scheme 43

1. Remove fast idle bracket and solenoid from injection pump. Loosen (keep snug) 3 nuts attaching fuel injection pump to pump mounting adapter with Injector Pump Wrench (T83T-9000-B).
2. Install Injection Pump Rotator (T83T-9000-C) on front of pump. Rotate pump to align injection pump mounting flange timing mark with pump mounting adapter timing mark. (Scheme 43) (Scheme 43): Static Timing Mark Alignment Keep mounting nuts snug during static timing check.
3. Remove tools and tighten mounting nuts. Visually recheck timing to ensure that marks are still aligned after tightening nuts.

Dynamic Timing (Engine Running)

Correct timing specifications vary with cetane value of engine fuel. Before performing timing test, determine cetane value as follows

Scheme 44

Scheme 45

1. Obtain a small fuel sample from injection system. Temperature of fuel must be 75-95°F (24-35°C) to obtain accurate results.
2. Fill hydrometer container included with Dynamic Timing Meter (078-00100) with fuel until hydrometer floats. Spin container gently to break surface tension of fuel.
3. Read number at lowest point of fuel level in hydrometer. Compare reading to «DIESEL FUEL CETANE VALUES»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) chart to determine Cetane value. DIESEL FUEL CETANE VALUES Hydrometer Reading Cetane Value.837 50.846 47.849 46.858 43.862 42.876 38
4. Start and warm engine to normal operating temperature. Coolant temperature MUST be 192-212°F (89-100°C) when performing dynamic timing procedure. Stop engine and install magnetic pick-up probe of Dynamic Timing Meter (78-0100) into timing pointer probe hole. (Scheme 44) (Scheme 44): Magnetic Pick-Up Probe Installation
5. Remove No. 1 cylinder glow plug. Install luminosity probe in place of glow plug and tighten to 12 ft. lbs. (16 N.m). (Scheme 45) Connect photocell over luminosity probe and connect to timing meter. Connect meter to battery and adjust offset on meter. (Scheme 45): Luminosity Probe Installation
6. Raise and support rear wheels. Place transmission in Neutral and start engine. Using Throttle Controller (014-00302), set engine speed at 1400 RPM with no accessory load. Read injection timing on meter.
7. If injection timing is not within 2° of value indicated in «DYNAMIC INJECTION TIMING SPECIFICATIONS»(/ford/cab-chassis-ranger/1985-1986/remont/testing-diagnostics/#fuel-injection-system-69l-diesel) chart, timing must be adjusted. If timing is not within specifications, stop engine and loosen pump retaining nuts (keeping nuts snug).
8. Using pump rotator, rotate pump clockwise to retard timing or counterclockwise to advance timing (as viewed from front of engine). Tap rotator with rubber mallet as needed to rotate pump.
9. Moving timing mark.030" (.75 mm) is equal to 2° of timing. Retighten nuts. Recheck timing using meter. Repeat step 8 as needed to obtain correct timing. Remove timing meter and other test equipment. Reinstall glow plug using anti-seize compound on threads.

TIMIMG SPECIFICATIONS

DYNAMIC INJECTION TIMING SPECIFICATIONS

CURB IDLE SPEED

1. Start and run engine until it reaches normal operating temperature. Idle speed is measured with man. trans. in Neutral or auto. trans. in "D". Adjust idle speed to specification as indicated on Emission Tune-Up Decal in engine compartment. Use curb idle screw on side of pump for adjustment.
2. Shift transmission out of gear and rev engine momentarily. Shift back into specified gear and recheck idle speed. Readjust if necessary.

FAST IDLE SPEED

1. Start and run engine until it reaches normal operating temperature. Disconnect wiring harness from fast idle solenoid. Apply battery voltage to solenoid to activate it. Rev engine momentarily to set solenoid plunger. Fast idle speed should be 850-900 RPM.
2. Adjust fast idle speed if necessary by turning solenoid plunger. Rev engine and recheck fast idle speed. Readjust if necessary. Remove battery voltage from solenoid and reconnect harness. (Scheme 46)

Throttle Adjustment Locations. Scheme 46

ACCELERATOR LINKAGE ADJUSTMENT

With engine off, check that throttle lever contacts injection pump stop at full accelerator depression. Adjust stop screw on throttle lever if necessary.

Scheme 47

Scheme 48

1. The vacuum regulator valve provides vacuum signals to control transmission shift points. Vacuum setting of valve should be checked periodically, using the following procedure. Engine MUST NOT be running during this procedure.
2. Disconnect 2-port vacuum connector from vacuum regulator valve, located on left side of pump. (Scheme 47) Remove throttle cable from pump throttle lever, located on right side of pump. (Scheme 47): Location of Vacuum Regulator Valve
3. Remove throttle return spring and reposition. Place end of spring over throttle lever ball stud and other end over throttle cable support bracket. Insert Gauging Block (T83T 7B200 AH) between pump boss and wide open throttle stop screw. (Scheme 48) (Scheme 48): Repositioning Throttle Return Spring Insert gauging block between pump boss and wide open throttle stop screw.
4. Attach a vacuum pump to upper port (labeled "VAC") of vacuum regulator valve. Attach vacuum gauge to lower port (labeled "TRANS") of regulator valve.
5. Apply and maintain 20 in. Hg to vacuum regulator valve. Vacuum gauge attached to regulator valve should indicate 6 1/2-7 1/2 in. Hg. If not, adjust regulator valve.
6. To adjust valve, loosen 2 vacuum regulator valve-to-injection pump mounting screws and rotate valve until vacuum gauge reads 6 1/2-7 1/2 in. Hg. Tighten screws. If valve cannot be adjusted to obtain vacuum reading, replace regulator valve.
7. Release vacuum and remove gauging block. Reconnect throttle return spring in original position and make sure fuel injection pump lever returns and stays at idle position.
8. Apply and maintain 20 in. Hg to vacuum regulator valve again. Vacuum gauge MUST indicate at least 13 in. Hg. If vacuum reading is less than 13 in. Hg, replace vacuum regulator valve and adjust new valve using above procedure.
9. Remove vacuum pump and gauge. Reconnect all disconnected components in their original positions.

WATER SEPARATOR

1. When water level in water separator reaches maximum level, a warning lamp on the dash will light up. When warning lamp is lit, it is necessary to drain water from the separator.
2. Stop vehicle and shut off engine. On pickup models, unscrew vent (located on top of separator) 2 1/2-3 turns. Unscrew drain (located on bottom of separator) 1-1 1/2 turns. Drain water into a container. Close vent and drain.
3. On Van models, locate water separator drain knob on left side of firewall under hood. Place a container under separator, located behind left front wheel. Pull knob out and hold for 45 seconds. Release knob and remove container.
4. On all models, restart engine and check warning lamp. If warning lamp is still lit, fuel system needs to be checked or repaired. The only serviceable item on the separator is the water level sensor.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TROUBLE SHOOTING
• GLOW PLUG TEST C
• GLOW PLUG TEST B
• GLOW PLUG TEST A
• GLOW PLUG TEST D
• GLOW PLUG TEST E
• GLOW PLUG SYSTEM TROUBLE SHOOTING
• GLOW PLUG LAMP TROUBLE SHOOTING