| Removal and Installation Special Tool(s) | | Hand Pressure Pump with Adaptor Kit 310-110 | General Equipment Pneumatic vacuum gun Fluid container Piece of clear tube 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: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: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:Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign material from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfunction. 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 material ingress to the fuel injection system. 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. | | -
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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Note the location of the engine cover retaining clips. | | | -
CAUTION:Care must be taken when releasing the fourth retaining clip and maneuvering the engine cover past the manifold absolute pressure (MAP) sensor. Failure to follow this instruction may result in damage to the MAP sensor. NOTE:Remove the engine cover in the sequence shown. Remove the engine cover. | | | -
Clean the fuel filter, fuel supply lines and surrounding areas.
For additional information, refer to: Fuel Injection Component Cleaning (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, General Procedures).
| 5. Remove the components in the order indicated in the following illustration(s) and table(s). 1 - Fuel filter crash protection top shield retaining bolts 2 - Fuel filter crash protection top shield 3 - Fuel filter electrical connector 6. To install, reverse the removal procedure. NOTE:Do not install the engine cover at this stage. | | -
Remove and discard the blanking caps from the fuel filter fuel supply line and fuel filter. | | | -
NOTE:Make sure the hand pressure pump arrow indicating the direction of fuel flow is pointing towards the fuel filter. Install the special tool between the fuel filter fuel supply line quick release coupling and the fuel filter union. | | | -
Loosen the fuel filter bleed screw (special tool shown removed for clarity). | | | -
Operate the hand pressure pump at least 30 times. | | | -
CAUTION:Do not over tighten the fuel filter bleed screw. Failure to follow this instruction may result in damage to the fuel filter bleed screw and in turn result in air ingress to the fuel system. Tighten the fuel filter bleed screw finger tight (special tool shown removed for clarity). | | | -
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 it to idle until it reaches normal operating temperature. | | | -
Connect the fuel filter fuel supply line.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
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Install the fuel filter crash protection top shield. | | | -
Install the engine cover. | | | -
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 3 : Fuel filter fuel supply line quick release coupling | | -
Clean the fuel filter, fuel supply lines and surrounding areas.
For additional information, refer to: Fuel Injection Component Cleaning (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, General Procedures).
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Disconnect the fuel filter fuel supply line.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
- Install a clean blanking cap to the fuel filter fuel supply line.
| Item 4 : Fuel filter to fuel pump fuel supply line quick release coupling | | -
Disconnect the fuel filter to fuel pump fuel supply line.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
- Install a clean blanking cap to the fuel filter to fuel pump fuel supply line.
| Installation Details Item 6 : Fuel filter NOTE:Make sure that the fuel filter is correctly installed into the support bracket. Item 4 : Fuel filter to fuel pump fuel supply line quick release coupling | | -
Remove and discard the blanking cap from the fuel filter to fuel pump fuel supply line. | | | -
Connect the fuel filter to fuel pump fuel supply line.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
| Item 3 : Fuel filter fuel supply line quick release coupling NOTE:Do not connect the fuel filter fuel supply line at this stage. NOTE:Do not install the fuel filter crash protection top shield at this stage. |
