| Removal and Installation Special Tool(s) | | Hand Pressure Pump with Adapter Kit 310-110 | General Equipment WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury. WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury. CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines. CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components to prevent foreign matter ingress to the components. | | -
Remove the Exhaust Gas Recirculation (EGR) cooler.
For additional information, refer to: Exhaust Gas Recirculation (EGR) Cooler (303-08C Engine Emission Control - 1.6L Duratorq-TDCi (DV) Diesel, Removal and Installation).
| 2. Remove the components in the order indicated in the following illustration(s) and table(s). 4 - Fuel filter fuel supply line and fuel pump fuel return line retaining clip See Removal Detail 10 - Fuel injection system fuel supply and return lines 12 - Glow plug wire retaining nuts 3. To install, reverse the removal procedure. | | -
Using the special tool, prime the fuel system. - Operate the hand pump until it becomes firm when squeezed.
- Squeeze and hold the hand pump for 10 seconds.
- Squeeze and hold the hand pump for a further 10 seconds.
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CAUTION:Do not operate the starter motor for longer than 10 seconds at a time. After 10 seconds, turn the ignition to position 0 and allow the starter motor to cool for 30 seconds before attempting to start the engine again. Start the engine and allow to idle until it reaches normal operating temperature. | | | -
Remove the hand pressure pump and connect the fuel supply line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
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Initialize the door window motors.
For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).
| Removal Details Item 2 : Fuel supply line quick release coupling | | -
Clean the fuel injector, fuel pump, fuel injection supply manifold, high-pressure fuel supply line and surrounding areas.
For additional information, refer to: Fuel Injection Component Cleaning (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, General Procedures).
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Detach the fuel supply line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
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Install blanking plugs to the open ends of the fuel supply line and fuel filter fuel supply line. | Item 3 : Fuel line quick release coupling
Item 6 : Fuel line quick release coupling
Item 7 : Fuel line quick release coupling
Item 8 : Fuel line quick release coupling
Item 9 : Fuel line quick release coupling | | -
Detach the quick release couplings.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
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Install blanking plugs to the open ends of the detached fuel line and fuel component. | Item 4 : Fuel filter fuel supply line and fuel pump fuel return line retaining clip | | -
Detach the fuel filter fuel supply line and fuel pump fuel return line from the intake manifold. | Item 5 : Fuel injector fuel return line connections | | -
Detach the fuel return line from the fuel injector. - Remove the fuel return line retaining clip.
- Detach the fuel return line.
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Install blanking plugs to the open ends of the fuel return lines and the fuel injectors. | Item 11 : Glow plug wire electrical connector | | -
Disconnect the glow plug wire electrical connector and detach the glow plug wire electrical connector from the retaining bracket. | Installation Details Item 9 : Fuel line quick release coupling
Item 8 : Fuel line quick release coupling
Item 7 : Fuel line quick release coupling
Item 6 : Fuel line quick release coupling
Item 3 : Fuel line quick release coupling | | -
Remove and discard the blanking plugs from the fuel line quick release couplings and fuel components. | | | -
Connect the fuel line quick release couplings.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
| Item 5 : Fuel injector fuel return line connections | | -
Remove and discard the blanking plugs from the fuel injectors and the fuel injector return line connections. | Item 2 : Fuel supply line quick release coupling | | -
NOTE:Make sure the hand pressure pump arrow indicating the direction of fuel flow is pointing towards the fuel filter. Remove and discard the blanking plugs. Install the special tool between the fuel tank fuel supply line quick release coupling and the fuel filter fuel supply line. | |
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