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Fuel Injection Pump > < Fuel Charging and Controls

Mondeo 2001 (10.2000-02.2007)

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

Special Tool(s)

Socket, Fuel Injector Remover/Installer

303-677 (21-236)

Aligner, Fuel Injector

303-711 (21-258)

Installer, Fuel Injector Seal

303-695

Installer, Fuel Injector Seal

303-1055

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

  1. Remove the high-pressure fuel supply lines.
    • Disconnect the high-pressure fuel supply line unions.
    • Discard the high-pressure fuel supply lines.

  1. Detach the fuel injector fuel return line.
    • Discard the fuel return line sealing washers.

  1. Remove the fuel injector seals.
    • Discard the fuel injector seals.

  1. NOTE:
    NOTE:The fuel injector locking collar must be fully loosened in order to remove the fuel injectors.
    Using the special tool, loosen the fuel injector locking collar and remove the fuel injectors by gently working them loose.

Installation

All vehicles
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. NOTE:
    NOTE:Do not tighten the fuel injector locking collar at this stage.
    Using the special tool, install the fuel injectors finger tight.

  1. Using the special tools, align and tighten the fuel injector locking collar.
Vehicles built up to 11/2002
  1. NOTE:
    NOTE:Install new fuel injector seals.
    Using the special tool, install the fuel injector seals.
Vehicles built 11/2002 onwards
  1. NOTE:
    NOTE:Install new fuel injector seals.
    Using the special tool, install the fuel injector seals.
All vehicles
  1. NOTE:
    NOTE:Install new fuel retaurn line sealing washers.
    Install the fuel injector fuel return line to the fuel injectors.

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

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

  1. Tighten the high-pressure fuel supply line unions to the fuel injection pump.

  1. Tighten the high-pressure fuel supply line unions to the fuel injectors.
  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).

Fuel Injection Pump > < Fuel Charging and Controls