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303-04D Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel|Specifications > < Fuel Pump

Mondeo 2007.5 (02.2007-)

Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel - Fuel Metering Valve Mondeo 2007.5 (02/2007-)
Removal and Installation

Special Tool(s)

Wrench, Fuel Pump Solenoid

303-1286
General Equipment
Bench vice fitted with soft jaws
Small screwdriver
Heat gun

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 fuel injection pump.
    For additional information, refer to: Fuel Pump (303-04D, Removal and Installation).

  1. CAUTION:
    CAUTION:Soft jaws must be used to prevent damage to the fuel injection pump.
    CAUTION:
    CAUTION:The fuel injection pump must not be retained by any machined faces or the fuel injection pump control unit.
    Using the cast mounting flange only, mount the fuel injection pump into a suitable bench vice fitted with soft jaws.

  1. Remove the mounting plate.
  1. Using the pneumatic vacuum gun, clean the area around the fuel injection one-way valves.

  1. Remove the fuel injection one-way valves.
    • Discard the fuel injection one-way valves.

  1. Using a clean small screwdriver, carefully remove the sealing washers.
    • Discard the sealing washers.

  1. Pull back the protection sleeve to expose the fuel injection pump wiring.

  1. Cut the wiring at the fuel metering valve.

  1. Using the special tool, loosen the fuel metering valve by 4 turns.

  1. Twist and pull the fuel metering valve to loosen the O-ring sealing washers.

  1. Remove the fuel metering valve.
    • Discard the fuel metering valve.

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. To aid installation, lightly lubricate the two fuel metering valve O-ring seals with Renap 220 oil (supplied in the parts kit).

  1. Install the sealing washer to the fuel metering valve (unless already pre-assembled).

  1. Finger tighten the fuel metering valve in a 10 o'clock position.

  1. Using the special tool, tighten the fuel metering valve.
    • Take a note of the amount that the fuel metering valve turns.
  1. Loosen the fuel metering valve. Turn the fuel metering valve back by the amount noted in the previous step, in order for the fuel metering valve to tighten in the 12 o'clock position.

  1. NOTE:
    NOTE:The fuel metering valve must be in the 12 o'clock position after final tightening.
    Using the special tool, tighten the fuel metering valve in two stages.
    • Stage 1: 25 Nm.
    • Stage 2: 50 degrees.
  1. If the fuel metering valve is not in the 12 o'clock position after final tightening, remove it, install a new sealing washer and repeat the installation steps.

  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. Install the fuel injection one-way valves.

  1. Cut the wires that connect into the fuel injection pump. Trim the end of the insulation to expose the wiring.

  1. Cut the wires that connect into the new metering valve. Trim the end of the insulation to expose the wiring.

  1. NOTE:
    NOTE:The fuel metering valve wiring can be connected to the fuel injection pump wiring either way round and it will not affect the function of the new fuel metering valve.
    Slide the protection sleeve and connector insulation sleeves (supplied in the parts kit) over the wiring. Join the fuel injection pump wiring to the fuel metering valve wiring by crimping the electrical connectors (supplied in the parts kit).

  1. CAUTION:
    CAUTION:The electrical connectors must be correctly sealed to prevent water ingress which could affect the operation of the fuel metering valve.
    Using a heat gun, heat shrink the connector insulation sleeves over the electrical connectors.

  1. Install the protection sleeve over the fuel injection pump wiring harness.

  1. Install the mounting plate.
  1. Install the fuel injection pump.
    For additional information, refer to: Fuel Pump (303-04D, Removal and Installation).

303-04D Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel|Specifications > < Fuel Pump