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Fuel Injection One-Way Valve > < Fuel Injectors

Mondeo 2001 (10.2000-02.2007)

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

Special Tool(s)

Remover/Installer, Crankshaft Oil Seal

303-679 (21-238)

Timing Tool, Crankshaft TDC

303-675 (21-234)

Locking Tool, Fuel Injection Pump Sprocket

303-1151

Socket, Fuel Injection Pump

310-083 (23-057)

Hand Pressure Pump with Adapter Kit

(310-110)
General Equipment
Dowel with a diameter of 6 mm and a length of 65 mm
Screwdriver

Removal

All vehicles
  1. 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.
    NOTE:
    NOTE:Fuel supply line connectors are white or are identified by a white band. Fuel return line connectors are red or are identified by a red band.
    Disconnect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

  1. Remove the engine cover.

  1. Detach the coolant expansion tank and secure it to one side.

  1. Detach the power steering fluid reservoir and secure it to one side.

  1. Remove the front engine mount damper.

  1. Using the special tool, remove the fuel injection pump sprocket access cover.
  1. Remove the crankshaft position (CKP) sensor.
    For additional information, refer to: Crankshaft Position (CKP) Sensor (303-14D Electronic Engine Controls - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).

  1. NOTE:
    NOTE:Turn the engine in the normal direction of rotation only.
    Turn the engine until the fuel injection pump sprocket timing hole is at the 12 o'clock position.

  1. CAUTION:
    CAUTION:Do not turn the engine when the special tool is fully located into the flywheel. Failure to follow this instruction will cause damage to the CKP sensor housing.
    NOTE:
    NOTE:Turn the engine in the normal direction of rotation only.
    NOTE:
    NOTE:When the special tool has locked the flywheel in position the fuel injection pump sprocket timing hole will be in the 1 o'clock position.
    Turn the engine to 50 degrees before top dead center (TDC) and insert the special tool through the CKP sensor hole.
  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. Disconnect the fuel injection pump control unit electrical connector.
    • Slide out the locking tang.

  1. Disconnect the high-pressure fuel supply line unions from the fuel injectors.

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

  1. Disconnect the fuel supply and fuel return lines.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Remove the fuel injection pump fuel supply and fuel return lines retaining bracket bolts.

  1. Using the special tool, support the fuel injection pump sprocket.

  1. NOTE:
    NOTE:Access the fuel pump retaining bolts through the holes provided in the special tool 303-1151 and fuel pump sprocket. The fuel pump retaining bolts cannot be completely removed.
    Using the special tool, remove the fuel injection pump retaining bolts.

  1. Remove the fuel injection pump sprocket retaining bolts.
Vehicles with 90 PS diesel engine
  1. Remove the fuel injection pump damper.
All vehicles
  1. Remove the fuel injection pump support bracket to cylinder block bolts (fuel injection pump shown removed for clarity).

  1. Remove the fuel injection pump support bracket to fuel injection pump bolts and remove the fuel injection pump.
    • Discard the gasket.

  1. Remove the fuel supply and fuel return lines.

Installation

All vehicles
  1. 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.
    NOTE:
    NOTE:If a new fuel injection pump is to be installed, it must be configured to the powertrain control module (PCM) using WDS before the engine can be started.
    NOTE:
    NOTE:Make sure that new high-pressure fuel supply lines are installed.
    Install the fuel supply and fuel return lines.

  1. NOTE:
    NOTE:Do not tighten the fuel injection pump support bracket to cylinder block bolts at this stage.
    Install the fuel injection pump support bracket to cylinder block bolts.

  1. Using a suitable piece of dowel with a diameter of 6 mm and a length of 65 mm, reset the fuel injection pump timing by inserting the dowel into the cut outs provided.
  1. Remove the suitable piece of dowel with a diameter of 6 mm and a length of 65 mm, from the fuel injection pump before installing the fuel injection pump to the cylinder block.

  1. NOTE:
    NOTE:Install a new fuel injection pump gasket.
    NOTE:
    NOTE:Do not tighten the fuel injection pump support bracket to fuel injection pump bolts at this stage.
    Install the fuel injection pump and install the fuel injection pump support bracket to fuel injection pump bolts.

  1. Using the special tool, tighten the fuel injection pump retaining bolts.

  1. Install the fuel injection pump sprocket retaining bolts finger tight.

  1. Remove the special tool.

  1. Insert the fuel injection pump timing dowel to check the fuel injection pump timing.

  1. Tighten the fuel injection pump sprocket retaining bolts.

  1. Tighten the fuel injection pump support bracket to fuel injection pump bolts.

  1. Tighten the fuel injection pump support bracket to cylinder block bolts (fuel injection pump shown removed for clarity).
Vehicles with 90 PS diesel engine
  1. Install the fuel injection pump damper.
All vehicles
  1. Remove the fuel injection pump timing dowel.
  1. Using a suitable paint, mark the position of the crankshaft pulley in relation to the engine front cover.

  1. Remove the special tool from the CKP sensor housing.
  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Turn the engine two revolutions.

  1. CAUTION:
    CAUTION:Do not turn the engine when the special tool is located fully into the flywheel. Failure to follow this instruction will cause damage to the CKP sensor housing.
    NOTE:
    NOTE:Only turn the engine in the normal direction of engine rotation.
    Turn the engine to 50 degrees before TDC and insert the special tool through the CKP sensor hole.

  1. Insert the fuel injection pump timing dowel to check the fuel injection pump timing.

  1. CAUTION:
    CAUTION:Do not remove the fuel injection pump sprocket retaining bolts. Failure to follow this instruction may result in damage to the engine.
    Loosen the fuel injection pump sprocket retaining bolts.

  1. CAUTION:
    CAUTION:Do not make any adjustments to the timing chain tension using the fuel injection pump retaining bolts or nuts. Failure to follow this instruction may result in damage to the engine.
    Using a suitable screwdriver turn the fuel injection pump sprocket counterclockwise to tension timing chain.

  1. Tighten the fuel injection pump sprocket retaining bolts.

  1. Remove the special tool from the CKP sensor housing.
  1. Install the CKP sensor.
    For additional information, refer to: Crankshaft Position (CKP) Sensor (303-14D Electronic Engine Controls - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).

  1. Remove the fuel injection pump timing dowel.

  1. Using the special tool, install the fuel injection pump sprocket access cover.

  1. NOTE:
    NOTE:Make sure the fuel injection pump electrical connector pins are clean.
    Install the fuel injection pump control unit electrical connector.

  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 fuel injection pump supply and return lines retaining bracket bolts.

  1. Connect the fuel pump supply and return lines.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
  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. Install the front engine mount damper.

  1. Attach the power steering fluid reservoir.

  1. Attach the coolant expansion tank.
  1. Connect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
Vehicles with 90 PS diesel engine
  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 return line regulating valve from the fuel filter.
    • Detach the retaining clip.

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

  1. Remove and discard the fuel filter.
    • Detach the retaining clip.

  1. NOTE:
    NOTE:Install a new fuel filter.
    Connect the fuel return line regulating valve and the fuel filter to fuel injection pump fuel supply line to 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. NOTE:
    NOTE:If a new fuel injection pump has been installed and difficulties occur getting fuel through the high-pressure system, it must be configured to the PCM using WDS before the high pressure fuel lines can be bled.
    Make sure the engine is still at TDC by checking the paint marks.

  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 46 and 47 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.
Vehicles with 115 PS diesel engine
  1. Disconnect the fuel return line regulating valve from the fuel filter.
    • Detach the retaining clip.

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

  1. Remove and discard the fuel filter.
    • Detach the retaining clip.

  1. NOTE:
    NOTE:Install a new fuel filter.
    Connect the fuel tank to fuel filter supply line and the fuel filter to fuel injection pump supply line to the fuel filter.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Connect the fuel return line regulating valve to the fuel filter.
    • Detach the retaining clip.

  1. Detach the left-hand front door weatherstrip.

  1. Detach the left-hand cowl side trim panel.

  1. Disconnect the inertia fuel shutoff (IFS) switch electrical connector.

  1. Using a suitable clear plastic tube and connectors, manufacture and install a bleed tube as shown.
    1. Connect the bleed tube to the return line from the fuel injection pump.
    1. Connect the bleed tube to the fuel filter.
    1. Place the bleed tube into a suitable container.

  1. Using a suitable container and piece of tubing, install one end of the tubing to the remaining open fitting on the T piece and place the other end of the tubing into the container.

  1. NOTE:
    NOTE:If a new fuel injection pump has been installed and difficulties occur getting fuel through the high-pressure system, it must be configured to the powertrain control module (PCM) using WDS before the high-pressure fuel supply lines can be bled.
    Using a fused 15A jumper wire, supply battery voltage to the fuel lift pump (IFS switch electrical connector pin 1) and visually inspect the clear pipe for visible signs of air.
  1. When no more air is visible in the clear pipe, disconnect the 15A jumper wire.
  1. Remove the clear plastic pipe and connectors and install the fuel injection pump return line.
  1. Make sure the engine is still at top dead center by checking the paint marks.

  1. Using a fused 15A jumper wire, supply battery voltage to the fuel lift pump (IFS switch electrical connector pin 1)

  1. NOTE:
    NOTE:Only one high-pressure fuel supply line union will show signs of fuel escaping.
    Visually inspect the high-pressure fuel supply lines and tighten the high-pressure fuel supply line union that shows signs of fuel escaping.
  1. NOTE:
    NOTE:Only turn the engine in the normal direction of engine rotation.
    Using the paint mark as reference, slowly turn the engine through 180 degrees.
  1. Repeat steps 74 to 75 to bleed the remaining three high-pressure fuel supply lines.
  1. Disconnect the fused 15A jumper wire from the IFS electrical connector.

  1. Remove the container and piece of tubing from the fuel pump to fuel filter fuel return line.

  1. Connect the IFS switch electrical connector.

  1. Attach the left-hand cowl side trim panel.

  1. Attach the left-hand front door weatherstrip.
All vehicles
  1. Install the engine cover.
  1. Initialize the door window motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

Fuel Injection One-Way Valve > < Fuel Injectors