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Valve Cover - Vehicles With: Common Rail Fuel Injection > < Intake Manifold

Mondeo 2001 (10.2000-02.2007)

Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel - Valve Cover Mondeo 2001 (10/2000-02/2007)
In-vehicle Repair

Special Tool(s)

Installer, Fuel Injector Seal

303-695

Installer, Fuel Injector Seal

303-1055

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 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 high-pressure fuel supply line unions from the fuel injectors.

  1. Remove the high-pressure fuel supply line unions from the fuel injection pump.
    • Discard the lines.

  1. Disconnect the fuel injector return line.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Remove the fuel injector return line.
    • Discard the return line and sealing washers.

  1. Disconnect the positive crankcase ventilation (PCV) hose from the valve cover.

  1. Remove the valve cover.
    • Discard the gasket and the seals.

Installation

All vehicles
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. NOTE:
    NOTE:Install a new valve cover gasket if necessary.
    Install the valve cover.
Vehicles built up to 11/2002
  1. NOTE:
    NOTE:Install new valve cover fuel injector seals.
    Using the special tool, install the valve cover fuel injector seals.
Vehicles built 11/2002 onwards
  1. NOTE:
    NOTE:Install new valve cover fuel injector seals.
    Using the special tool, install the valve cover fuel injector seals.
All vehicles
  1. Connect the PCV hose to the valve cover.

  1. NOTE:
    NOTE:Install a new fuel injector return line.
    Install the fuel injector return line.

  1. Connect the fuel injector return line to the fuel injectors.

  1. NOTE:
    NOTE:Install new high-pressure fuel supply lines.
    NOTE:
    NOTE:Do not tighten the high-pressure fuel supply line unions at this stage.
    Install the high-pressure fuel supply line unions to the fuel injection pump.

  1. NOTE:
    NOTE:Do not tighten the high-pressure fuel supply line unions at this stage.
    Connect the high-pressure fuel supply line unions to the fuel injectors.

  1. Tighten the high-pressure fuel supply line unions to the fuel injection pump.

  1. Tighten the high-pressure fuel supply line unions to the fuel injectors.
  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).

Valve Cover - Vehicles With: Common Rail Fuel Injection > < Intake Manifold