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Fuel Pump > < Fuel Injection Component Cleaning

Mondeo 2001 (10.2000-02.2007)

Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (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)
General Equipment
Worldwide Diagnostic System (WDS)
Pneumatic vacuum gun

Removal

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.
WARNING:
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.
WARNING:
WARNING:Do not carry out any repairs to the fuel injection system with the engine running. The fuel pressure within the system can be as high as 1600 bar. Failure to follow this instruction may result in personal injury.
WARNING:
WARNING:Do not carry out any repairs to the fuel injection system without checking that the fuel pressure has dropped to zero and that the fuel temperature has either reached ambient temperature or is below 30º C. whichever is the greater. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:Wait at least one minute after the engine stops before commencing any repair to the fuel injection system. Failure to follow this instruction may result in personal injury.
CAUTION:
CAUTION:Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfuction.
CAUTION:
CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
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.
CAUTION:
CAUTION:Do not disassemble the fuel injectors or clean the nozzles, even with an ultrasonic cleaner. Always install new fuel injectors when required.
  1. Using datalogger in WDS, check that the fuel pressure has dropped to zero and that the fuel temperature has either reached ambient temperature or is below 30º C. whichever is the greater.
  1. 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 upper cover.
  1. CAUTION:
    CAUTION:Protect the fuel injector electrical connectors with lint-free material to prevent contamination from the cleaning fluid.
    Clean the fuel injector, high-pressure fuel supply line and surrounding areas.
    For additional information, refer to: Fuel Injection Component Cleaning (303-04E Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, General Procedures).

  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel injector and the fuel injection supply manifold until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    CAUTION:
    CAUTION:Make sure the tool used to loosen the high-pressure fuel supply line unions is used at the top of the unions as this is where there is most material. Failure to follow this instruction may result in damage to the unions.
    CAUTION:
    CAUTION:Make sure that the fuel injector does not move when loosening the high-pressure fuel supply lines. Failure to follow this instruction will result in damage to the fuel injector and the fuel injector sealing washer.
    Loosen the high-pressure fuel supply lines from the fuel injectors and fuel injection supply manifold.
  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel injector and the fuel injection supply manifold until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply line, the fuel injector and the fuel injection supply manifold.
  1. Remove and discard the high-pressure fuel supply lines.
  1. Using the pneumatic vacuum gun, vacuum foreign material from the fuel injector and the fuel injection supply manifold.
  1. Install blanking caps to the open threaded ports on the fuel injector and the fuel injection supply manifold.

  1. Disconnect the fuel injector electrical connector.
Vehicles built up to 12/2002
  1. NOTE:
    NOTE:Discard the fuel return line if three or more new injectors are being installed.
    Disconnect the fuel return lines from the fuel injectors.
    • Release the locking tangs.
    • Position the fuel injector fuel return lines to one side.

  1. NOTE:
    NOTE:The blanking cap will have to be removed from the fuel injector for the fuel return line retaining collar to be removed. Once this is done re-install the blanking cap to the fuel injector.
    Remove the fuel return line retaining collar.
Vehicles built 12/2002 onwards
  1. NOTE:
    NOTE:Discard the fuel return line if three or more new injectors are being installed.
    Disconnect the fuel return lines from the fuel injectors.
    • Release the locking tangs.
    • Position the fuel injector fuel return lines to one side.
All vehicles
  1. Remove the valve cover fuel injector seal.
    • Discard the valve cover fuel injector seal.

  1. CAUTION:
    CAUTION:Make sure that the fuel injector does not move when loosening the fuel injector locking collar. Failure to follow this instruction will result in damage to the fuel injector and the fuel injector sealing washer.
    Using the special tool, remove the fuel injector.

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.
WARNING:
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:
CAUTION:Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfuction.
CAUTION:
CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
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.
CAUTION:
CAUTION:Do not disassemble the fuel injectors or clean the nozzles, even with an ultrasonic cleaner. Always install new fuel injectors when required.
NOTE:
NOTE:Install new high-pressure fuel supply lines.
NOTE:
NOTE:Install a new valve cover fuel injector seal.
NOTE:
NOTE:Install a new injector nut O-ring seal (if equipped).
  1. Record the identification code from the new fuel injector to upload into WDS during configuration (graphic shows an example of the identification code only).

  1. NOTE:
    NOTE:Do not tighten the fuel injector locking collar at this stage.
    Using the special tool, install the fuel injector.

  1. Using the special tools, tighten the fuel injector locking collar.

  1. Install the valve cover fuel injector seal.
Vehicles built 12/2002 onwards
  1. NOTE:
    NOTE:Install a new fuel return line if three or more new injectors are being installed.
    Connect the fuel return lines to the fuel injectors.
Vehicles built up to 12/2002
  1. NOTE:
    NOTE:The blanking cap will have to be removed from the fuel injector for the fuel return line retaining collar to be installed. Once this is done re-install the blanking cap to the fuel injector.
    Install the fuel return line retaining collar.

  1. NOTE:
    NOTE:Install a new fuel return line if three or more new injectors are being installed.
    NOTE:
    NOTE:An audible click should be heard when the fuel return line is pushed fully into the fuel injector.
    Connect the fuel return lines to the fuel injectors.
All vehicles
  1. Connect the fuel injector electrical connector.

  1. Loosen the fuel injection supply manifold retaining bolts (all high-pressure fuel supply lines shown removed for clarity).

  1. Loosen the fuel injection supply manifold support brackets (all high-pressure fuel supply lines shown removed for clarity).

  1. Loosen the fuel injection supply manifold retaining bolt (all high-pressure fuel supply lines shown removed for clarity).

  1. Using a suitable multipurpose lubricant spray, lubricate the high-pressure fuel supply line union threads.
  1. CAUTION:
    CAUTION:Do not allow the unions to hit the olive ends of the high-pressure fuel supply line as this may damage the ends of the line and allow foreign matter enter the fuel injection system.
    Position the high-pressure fuel supply line as near to the final installation position as possible and then remove and discard the blanking plugs from the high-pressure fuel supply line.
  1. Remove the blanking plugs from the fuel injectors and the fuel injection supply manifold threaded ports.
    • Discard the blanking plugs.

  1. CAUTION:
    CAUTION:Maintain pressure on the high-pressure fuel supply line to keep the olives in contact with the fuel injectors and the fuel injection supply manifold cones while installing the unions.
    NOTE:
    NOTE:Install the high-pressure fuel supply lines to the fuel injection supply manifold end first followed by the fuel injector end.
    NOTE:
    NOTE:Do not tighten the high-pressure fuel supply line unions at this stage.
    Install new high-pressure fuel supply lines.

  1. Tighten the fuel injection supply manifold support brackets retaining bolts.

  1. Tighten the fuel injection supply manifold retaining bolts.

  1. CAUTION:
    CAUTION:Make sure the special tool is clamped around the fuel injector which is being tightened and is resting up against the adjacent fuel injector.
    CAUTION:
    CAUTION:Make sure the tool used to tighten the high-pressure fuel supply line unions is used at the top of the union as this is where there is most material. Failure to follow this instruction may result in damage to the union.
    CAUTION:
    CAUTION:Make sure that the fuel injector does not move when tightening the high-pressure fuel supply lines. Failure to follow this instruction will result in damage to the fuel injector and the fuel injector sealing washer.
    Install the special tool and tighten the high-pressure fuel supply line union(s) at the fuel injector(s)
  1. Repeat step 17 for tightening the three remaining high-pressure fuel supply line unions at the fuel injectors.
  1. Remove the special tool.

  1. CAUTION:
    CAUTION:Make sure the tool used to tighten the high-pressure fuel supply line unions is used at the top of the union as this is where there is most material. Failure to follow this instruction may result in damage to the union.
    Tighten the high-pressure fuel supply line unions at the fuel injection supply manifold.

  1. Install the engine upper cover.
  1. Connect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Using WDS in module programming, configure the new fuel injector to the injector driver module (IDM).
  1. Initialize the door window motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

Fuel Pump > < Fuel Injection Component Cleaning