| In-vehicle Repair Special Tool(s) | | Hand Pressure Pump with Adapter Kit 310-110 | General Equipment Pneumatic vacuum gun Worldwide Diagnostic System (WDS) | | -
Using datalogger in WDS, check that the fuel pressure has dropped to zero and that the fuel temperature is below 30°C. | | | -
Disconnect the battery ground cable.
For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
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Remove the cowl panel grille.
For additional information, refer to: Cowl Panel Grille - Vehicles Built Up To: 03/2007 (501-02 Front End Body Panels, Removal and Installation).
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Remove the exhaust gas recirculation (EGR) cooler.
For additional information, refer to: Exhaust Gas Recirculation (EGR) Cooler (303-08C Engine Emission Control - 1.6L Duratorq-TDCi (DV) Diesel, Removal and Installation).
| 5. Remove the components in the order indicated in the following illustration(s) and table(s). 2 - Fuel injector harness trunking retaining bolts 3 - Fuel injector electrical connectors 4 - Fuel injector harness trunking 8 - Fuel injection system fuel supply and return lines 10 - High-pressure fuel supply lines 11 - Turbocharger outlet pipe 12 - Manifold absolute pressure (MAP) sensor electrical connector 13 - Exhaust gas recirculation (EGR) tube retaining bolts 14 - Throttle body retaining bracket retaining bolts 16 - Oil separator and intake manifold assembly 17 - Intake manifold O-ring seals All vehicles | | -
To install, reverse the removal procedure. | | | -
Using the special tool, prime the fuel system. - Operate the hand pump until it becomes firm when squeezed.
- Squeeze and hold the hand pump for 10 seconds.
- Squeeze and hold the hand pump for a further 10 seconds.
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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. | Vehicles with global closing | | -
Initialize the door window motors.
For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).
| Removal Details Item 5 : Fuel supply lines quick release couplings | | -
Install new blanking plugs to the open ends of the fuel supply line, fuel filter, fuel pump and fuel supply pipe. | | | -
Disconnect the fuel supply lines quick release couplings.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
| Item 6 : Fuel filter fuel supply line and fuel pump fuel return line retaining clip | | -
Detach the fuel filter fuel supply line and fuel pump fuel return line from the intake manifold. | Item 7 : Fuel injector fuel return line connections | | -
Detach the fuel return line from the fuel injector. - Remove the fuel return line retaining clip.
| Item 9 : High-pressure fuel supply line unions | | -
CAUTION:Do not allow the unions to hit the ends of the high-pressure fuel supply line. Failure to follow this instruction may result in damage to the ends of the line and allow foreign material to enter the fuel injection system. CAUTION:Make sure the tool used to tighten 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. NOTE:Maintain pressure on the high-pressure fuel supply line to keep the line in contact with the fuel injector cone and fuel injection supply manifold while installing the unions. NOTE:If it is not possible to correctly install the new high-pressure fuel supply line, it will be necessary to remove the remaining high-pressure fuel supply lines and to loosen the fuel injection supply manifold to allow correct alignment. Clean the fuel injector, fuel injection supply manifold, high-pressure fuel supply line and surrounding areas.
For additional information, refer to: Fuel Injection Component Cleaning (303-04D Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, General Procedures).
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Detach the high-pressure fuel supply line unions from the fuel injector and the fuel injection supply manifold. | | | -
Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply line, the fuel injector and the fuel injection supply manifold. | | | -
Remove and discard the high-pressure fuel supply lines. | | | -
Install new blanking plugs to the open threaded ports on the fuel injectors and the fuel injection supply manifold. | Item 15 : Oil separator and intake manifold assembly retaining bolts | | -
NOTE:Remove the oil separator and intake manifold assembly retaining bolts in the sequence shown. Remove the oil separator and the intake manifold assembly retaining bolts. | Installation Details Item 15 : Oil separator and intake manifold assembly retaining bolts | | -
NOTE:Install the oil separator and the intake manifold assembly retaining bolts in the sequence shown. Install the oil separator and the intake manifold assembly retaining bolts. | Item 9 : High-pressure fuel supply line unions CAUTION:Do not allow the unions to hit the ends of the high-pressure fuel supply line. Failure to follow this instruction may result in damage to the ends of the line and allow foreign material to enter the fuel injection system. CAUTION:Make sure the tool used to tighten 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. NOTE:Maintain pressure on the high-pressure fuel supply line to keep the line in contact with the fuel injector cone and fuel injection supply manifold while installing the unions. NOTE:If it is not possible to correctly install the new high-pressure fuel supply line, it will be necessary to remove the remaining high-pressure fuel supply lines and to loosen the fuel injection supply manifold to allow correct alignment. | | -
Using a suitable pneumatic vacuum gun, vacuum foreign material from the area around the fuel injectors and the fuel injection supply manifold. | | | -
Remove and discard the blanking plugs from the open threaded ports on the fuel injectors and the fuel injection supply manifold. | | | -
Install the fuel injector high-pressure fuel supply lines. | | | -
NOTE:Individual high-pressure fuel supply lines must have both unions tightened to Stage 1 and then Stage 2 before continuing on to the next high-pressure fuel supply line. Failure to follow this instruction may result in damage to the high-pressure fuel supply lines. Tighten the high-pressure fuel line unions in two stages. | Item 7 : Fuel injector fuel return line connections | | -
Remove and discard the blanking plugs from the fuel injectors and the fuel injector return line connections. | Item 6 : Fuel filter fuel supply line and fuel pump fuel return line retaining clip | | -
Tape the fuel lines with fabric tape. | Item 5 : Fuel supply lines quick release couplings | | -
Remove and discard the blanking plugs from the open ends of the fuel supply line, fuel filter, fuel pump and fuel supply pipe. | | | -
Connect the fuel line quick release couplings.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
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