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Fuel Injection Supply Manifold > < Fuel Injectors

Mondeo 2001 (10.2000-02.2007)

Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel - Fuel Pump Mondeo 2001 (10/2000-02/2007)
Removal and Installation

Special Tool(s)

Remover/Installer, Crankshaft Oil Seal

303-679 (21-238)

Locking Tool, Fuel Pump Sprocket

303-1151

Socket, Fuel Injection Pump

310-083 (23-057)
General Equipment
Worldwide Diagnostic System (WDS)
Pneumatic vacuum gun
Materials
Name
Specification
Loctite 572
WSK-M2G350-A1 

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.
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 malfunction.
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 or clean inside the fuel pump, even with an ultrasonic cleaner. Always install a new fuel pump when required.
All vehicles
  1. Using datalogger in WDS, check that the fuel pressure has dropped to zero and that the fuel temperature has 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. 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. Using the special tool, remove the fuel pump sprocket access cover.

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

  1. NOTE:
    NOTE:Do not remove the fuel pump retaining bolts at this stage.
    Install the special tool into the fuel pump to locate the fuel pump retaining bolts.

  1. Disconnect the glow plug wire electrical connector.
Vehicles built 07/2002 onwards
  1. Remove the exhaust gas recirculation (EGR) cooler to EGR valve tube.
    For additional information, refer to: Exhaust Gas Recirculation (EGR) Cooler to EGR Valve Tube (303-08C Engine Emission Control - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
Vehicles built 12/2003 onwards
  1. Disconnect the fuel injector to fuel pump fuel return line and fuel pump to fuel filter return line.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
    • Install blanking plugs to the open orifices.

  1. Disconnect the fuel pump fuel supply line.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
    • Install blanking plugs to the open orifices.

  1. Detach the fuel pump fuel supply and fuel return lines from the retaining clips and position them to one side.
All vehicles
  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 metering valve and fuel temperature sensor electrical connectors and protect them with lint-free material to prevent contamination from the cleaning fluid.

  1. Remove the high-pressure fuel supply line clamp.
  1. Clean the fuel pump, 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 the tool used to loosen the high-pressure fuel supply line union 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.
    Loosen the high-pressure fuel supply line at the fuel pump.
  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel pump 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 and the fuel pump.

  1. CAUTION:
    CAUTION:Make sure the tool used to loosen the high-pressure fuel supply line union 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:While maintaining the pressure on the high-pressure fuel supply line, clean and vacuum foreign material from the line and union.
    Remove and discard the high-pressure fuel supply line.
  1. Using the pneumatic vacuum gun, vacuum foreign material from the fuel pump and the fuel injection supply manifold.
  1. Install blanking caps to the open threaded ports on the fuel pump and the fuel injection supply manifold.
Vehicles built up to 12/2003
  1. Disconnect the fuel injector to fuel pump fuel return line and detach the line from the retaining clip.
    • Install blanking plugs to the fuel injector to fuel pump fuel return line male and female connectors.

  1. Disconnect the fuel pump fuel supply and fuel return lines.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
    • Install blanking plugs to the fuel pump fuel supply and fuel return line male and female connectors.

  1. Detach the fuel pump fuel supply and fuel return lines retaining bracket from the cylinder head.
    1. Loosen the retaining bolt.
    1. Remove the retaining nut.
    1. Slide the fuel pump fuel supply and fuel return lines retaining bracket up and position it to one side.
All vehicles
  1. Using the special tool, support the fuel 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 pump retaining bolts.

  1. Remove the fuel pump sprocket retaining bolts.

  1. Remove the fuel pump support bracket to cylinder block retaining bolts and remove the fuel pump.
    • Discard the fuel pump gasket.

  1. Remove the fuel pump support bracket from the fuel pump.

  1. Remove the fuel pump shield from the fuel pump.
Vehicles built up to 12/2003
  1. Remove the fuel pump fuel supply line from the fuel pump.
    • Discard the fuel pump fuel supply line union nut.

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.
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 malfunction.
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 or clean inside the fuel pump, even with an ultrasonic cleaner. Always install a new fuel pump when required.
NOTE:
NOTE:Install a new fuel pump gasket.
NOTE:
NOTE:Install a new high-pressure fuel supply line.
Vehicles built up to 12/2003
  1. Install the fuel pump fuel supply line to the fuel pump.
    • Install a new fuel pump fuel supply line union nut.
All vehicles
  1. Install the fuel pump shield to the fuel pump retaining bolts finger tight.

  1. NOTE:
    NOTE:Do not fully tighten the fuel pump support bracket bolts at this stage.
    Install the fuel pump support bracket to the fuel pump finger tight.

  1. NOTE:
    NOTE:Install a new fuel pump gasket.
    NOTE:
    NOTE:Apply a small bead of loctite 572 on the fuel pump retaining bolts.
    NOTE:
    NOTE:Do not tighten the fuel pump support bracket to cylinder block retaining bolts at this stage.
    NOTE:
    NOTE:Do not tighten the fuel pump retaining bolts at this stage.
    NOTE:
    NOTE:Install the fuel pump retaining bolts evenly in order to pull the fuel pump squarely into position.
    Install the fuel pump and fuel pump support bracket to cylinder block retaining bolts finger tight.

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

  1. Install the fuel pump sprocket retaining bolts.

  1. Remove the special tool.

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

  1. Tighten the fuel pump support bracket to cylinder block retaining bolts.

  1. Tighten the fuel pump support bracket retaining bolts (fuel pump shown removed for clarity).

  1. Tighten the fuel pump shield to the fuel pump.
Vehicles built up to 12/2003
  1. Remove the blanking plugs and connect the fuel injector to fuel pump fuel return line and attach the line to the retaining clip.
    • Discard the blanking plugs.

  1. Attach the fuel pump fuel supply and fuel return lines retaining bracket to the cylinder head.
    1. Install the fuel pump fuel supply and fuel return lines retaining bracket onto the retaining stud.
    1. Install the retaining nut.
    1. Tighten the retaining bolt.

  1. Remove the blanking plugs and connect the fuel pump fuel supply and fuel return lines.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
    • Discard the blanking plugs.
All vehicles
  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 to 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 pump and fuel injection supply manifold threaded ports.
    • Discard the blanking plugs.

  1. CAUTION:
    CAUTION:Do not tighten the high-pressure fuel supply line union at this stage.
    CAUTION:
    CAUTION:Maintain pressure on the high-pressure fuel supply line to keep the olive in contact with the fuel pump cone while installing the union. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    Install the high-pressure fuel supply line to the fuel pump.

  1. CAUTION:
    CAUTION:Do not tighten the high-pressure fuel supply line union at this stage.
    CAUTION:
    CAUTION:Maintain pressure on the high-pressure fuel supply line to keep the olive in contact with the fuel injection supply manifold cone while installing the union. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    Install the high-pressure fuel supply line to the fuel injection supply manifold.

  1. Install the high-pressure fuel supply line clamp.

  1. CAUTION:
    CAUTION:Make sure the tool used to tighten the high-pressure fuel supply line union 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 the tool used to tighten the high-pressure fuel supply line union does not come into contact with the inlet metering valve while tightening the high-pressure fuel supply line union. Failure to follow this instruction may result in fuel leaking from the union.
    Tighten the high-pressure fuel supply line at the fuel pump.

  1. CAUTION:
    CAUTION:Make sure the tool used to tighten the high-pressure fuel supply line union 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 at the fuel injection supply manifold.

  1. Connect the fuel metering valve and fuel temperature sensor electrical connectors.
  1. Remove the special tool.
  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).
Vehicles built 12/2003 onwards
  1. Connect the fuel injector to fuel pump fuel return line and fuel pump to fuel filter return line.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
    • Discard the blanking plugs.

  1. Connect the fuel pump fuel supply line.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
    • Discard the blanking plugs.

  1. Attach the fuel pump fuel supply and fuel return lines to the retaining clips.
Vehicles built 07/2002 onwards
  1. Install the EGR cooler to EGR valve tube.
    For additional information, refer to: Exhaust Gas Recirculation (EGR) Cooler to EGR Valve Tube (303-08C Engine Emission Control - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
All vehicles
  1. Connect the glow plug wire electrical connector.

  1. Attach the power steering fluid reservoir.

  1. Attach the coolant expansion tank.

  1. Install the engine upper cover.
  1. Install the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Initialize the door window motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).
  1. Install a new fuel filter.
    For additional information, refer to: Fuel Filter - 2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).

Fuel Injection Supply Manifold > < Fuel Injectors