| In-vehicle Repair 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 vapors are always present and may ignite. Failure to follow these instructions may result in personal injury. WARNING:Do not carry out any repairs to the fuel injection system with the engine running. The fuel pressure within the system is approximately 1600 bar. Failure to follow these instructions may result in personal injury. WARNING:Wait at least one minute after the engine stops before commencing any repair to the fuel injection system. Failure to follow these instructions may result in personal injury. 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. | | -
Remove the cowl panel grille.
For additional information, refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
| | | -
NOTE:The engine upper cover is held in place by three ball clips. The ball clips are not vertical, but are angled backwards by approximately 20 degrees. Location of the engine upper cover ball clips. | | | -
CAUTION:Contact of the engine upper cover with the cowl panel may cause damage (scratches) on the engine upper cover. If the ambient temperature is below 0° C, detach the engine upper cover with extreme caution. Failure to follow this instruction may cause the engine upper cover to be damaged. NOTE:Only remove and install the engine upper cover in the sequence shown. Remove the engine upper cover. - Detach the engine upper cover ball clips in the sequence shown.
| | | -
Disconnect the battery ground cable.
For additional information, refer to: Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures).
| | | -
Remove the fuel injectors. For additional information, refer to: (303-04E Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel) Fuel Injectors - VIN Plate Emission Level Code: S (Removal and Installation), Fuel Injectors - VIN Plate Emission Level Code: S (Removal and Installation). | 6. Remove the components in the order indicated in the following illustration(s) and table(s). 1 - Exhaust gas recirculation (EGR) pipe clamp 3 - Positive crankcase ventilation (PCV) hose 4 - Throttle body retaining bolts 5 - Throttle housing O-ring seal 7 - EGR pipe retaining bolts 11 - Camshaft position (CMP) sensor electrical connector 15 - Intake manifold assembly seals All vehicles | | -
To install, reverse the removal procedure. | | | -
Apply soap solution to the ball clip mountings in the engine upper cover. - Soap solution (maximum concentration of soap in water 1:200).
| | | -
CAUTION:Contact of the engine upper cover with the cowl panel may cause damage (scratches) on the engine upper cover. Failure to follow this instruction may cause the engine upper cover to be damaged. Put the engine cover into installation position and clip it in place by pressing at the places shown. - Make sure that the engine upper cover is fully engaged in the area of the fuel filter, if necessary apply more pressure in the areas shown.
| 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 9 : Fuel injector electrical connectors | | -
Clean the area around the fuel injectors.
For additional information, refer to: Fuel Injection Component Cleaning (303-04E Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, General Procedures).
| Item 13 : Timing belt upper cover | | -
Detach the engine wiring harness from the timing belt upper cover. | | | -
Remove the timing belt upper cover. | Item 14 : Intake manifold assembly | | -
Remove the intake manifold assembly retaining bolts in the sequence shown. | | | -
Detach the fuel temperature sensor from the intake manifold assembly. | Installation Details Item 14 : Intake manifold assembly | | -
Attach the fuel temperature sensor to the intake manifold assembly. | | | -
NOTE:Do not fully tighten the intake manifold assembly retaining bolts at this stage. Install the intake manifold assembly. - Install the 55 mm long bolt at position 14.
- Install the 70 mm long bolts at position 16 and 17.
| | | -
Tighten the intake manifold assembly retaining bolts in the sequence shown in two stages. | Item 13 : Timing belt upper cover | | -
Install the timing belt upper cover. | | | -
Attach the engine wiring harness to the timing belt upper cover. | Item 12 : CMP sensor | | -
NOTE:Only rotate the crankshaft in the normal direction of rotation. Position one of the camshaft pulley spokes in an upright position. | | | -
Install the CMP sensor. - If installing a new CMP sensor, position the CMP sensor so that the tip of the sensor is in contact with the camshaft pulley and tighten the retaining bolt.
- If installing the original CMP sensor, position the CMP sensor so that the tip of the sensor is in contact with the camshaft pulley.
2. Pull back the CMP sensor until the distance between the CMP sensor and the intake manifold = YY + 1.2 mm, and tighten the retaining bolt. | |
 Diesel/Description and Operation/Diagnosis and Testing/In-vehicle Repair//img/E50527.jpg)
 Diesel/Description and Operation/Diagnosis and Testing/In-vehicle Repair//img/E50472.jpg)
 Diesel/Description and Operation/Diagnosis and Testing/In-vehicle Repair//img/E50473.jpg)
 Diesel/Description and Operation/Diagnosis and Testing/In-vehicle Repair//img/E42749.jpg)
 Diesel/Description and Operation/Diagnosis and Testing/In-vehicle Repair//img/E42750.jpg)
 Diesel/Description and Operation/Diagnosis and Testing/In-vehicle Repair//img/E43417.jpg)
 Diesel/Description and Operation/Diagnosis and Testing/In-vehicle Repair//img/E42751.jpg)
 Diesel/Description and Operation/Diagnosis and Testing/In-vehicle Repair//img/E42752.jpg)
 Diesel/Description and Operation/Diagnosis and Testing/In-vehicle Repair//img/E42700.jpg)
