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Fuel Metering Valve > < Fuel Injection Pump
Fuel Charging and Controls - 2.0L Duratorq-Di/TDDi (Puma) Diesel - Fuel Injection One-Way Valve Mondeo 2001 (10/2000-02/2007)
Removal and Installation

Special Tool(s)

Hand Pressure Pump with Adapter Kit

310-110

General Equipment
Pneumatic vacuum gun
Small screwdriver

Removal

WARNING:
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.
CAUTION:
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.
  1. Remove the intake manifold.
    For additional information, refer to: Intake Manifold (303-01E Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
  1. Using the pneumatic vacuum gun, clean the area around the high-pressure fuel supply lines.

  1. Disconnect the high-pressure fuel supply line unions from the fuel injectors.
  1. Using the pneumatic vacuum gun, clean the area around the high-pressure fuel supply lines.

  1. Disconnect the high-pressure fuel supply line unions from the fuel injection pump.
    • Discard the fuel supply lines.

  1. NOTE:
    NOTE:Fuel injection pump shown removed for clarity.
    Remove the fuel injection one-way valves.
    • Discard the fuel injection one-way valves.

  1. NOTE:
    NOTE:Fuel injection pump shown removed for clarity.
    Using a clean small screwdriver, carefully remove the sealing washers.
    • Discard the sealing washers.

Installation

WARNING:
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.
CAUTION:
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.

  1. Lubricate the fuel injection one-way valves with Renap 220 oil (supplied in the parts kit).

  1. Position the sealing washers onto the end of the fuel injection one-way valves.

  1. NOTE:
    NOTE:Fuel injection pump shown removed for clarity.
    Install the fuel injection one-way valves.

  1. NOTE:
    NOTE:Install new high-pressure fuel supply lines.
    NOTE:
    NOTE:Do not tighten the high-pressure fuel supply line unions to the fuel injection pump at this stage.
    Connect the high-pressure fuel supply line unions to the fuel injection pump.

  1. NOTE:
    NOTE:Do not tighten the high-pressure fuel supply line unions to the fuel injectors at this stage.
    Connect the high-pressure fuel supply line unions to the fuel injectors.

  1. Tighten the high-pressure fuel supply line unions to the fuel injection pump.
  1. Install the intake manifold.
    For additional information, refer to: Intake Manifold (303-01E Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
  1. CAUTION:
    CAUTION:The generator must be protected from contamination. Failure to follow this instruction may cause premature failure of the generator.
    Protect the generator with lint-free material to prevent contamination.

  1. Disconnect the fuel tank to fuel filter fuel supply line from the fuel filter.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Install the hand pressure pump special tool adapter to the fuel tank to fuel filter fuel supply line.

  1. NOTE:
    NOTE:Make sure that the hand primer arrow indicating the fuel flow is pointing towards the fuel filter.
    Install the hand pressure pump special tool to the hand pressure pump special tool adapter.

  1. CAUTION:
    CAUTION:Make sure that the fuel filter connection is not damaged with the installation of the special tool, as this may cause air ingress to the fuel lines.
    Install the hand pressure pump special tool adapter to the fuel filter.

  1. NOTE:
    NOTE:Make sure that the hand primer arrow indicating the fuel flow is pointing towards the fuel filter.
    Install the hand pressure pump special tool to the hand pressure pump special tool adapter.
  1. Operate the hand pressure pump special tool until fuel starts to flow through the fuel filter.
  1. Using a suitable paint, mark the position of the crankshaft pulley in relation to the engine front cover.

  1. NOTE:
    NOTE:Only one high-pressure fuel supply line will show signs of fuel escaping.
    Operate the hand pressure pump special tool and tighten the high-pressure fuel supply line union which shows signs of fuel escaping.
  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Using the paint marks as a reference slowly turn the engine through 180 degrees.
  1. Repeat steps 17 and 18 to bleed the three remaining high-pressure fuel supply lines.
  1. Remove the lint-free material from the generator.
  1. CAUTION:
    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.
  1. Switch the engine off.
  1. CAUTION:
    CAUTION:The generator must be protected from contamination. Failure to follow this instruction may cause premature failure of the generator.
    Protect the generator with lint-free material to prevent contamination.

  1. Remove the hand pressure pump special tool from the hand pressure pump special tool adapter.

  1. Remove the hand pressure pump special tool adapter from the fuel filter.

  1. Remove the hand pressure pump special tool from the hand pressure pump special tool adapter.

  1. Remove the hand pressure pump special tool adapter from the fuel tank to fuel filter fuel supply line.

  1. Connect the fuel tank to fuel filter fuel supply line to the fuel filter.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
  1. Remove the lint-free material from the generator.

Fuel Metering Valve > < Fuel Injection Pump