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303-04E Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma) Diesel|Specifications > < Fuel Return Line Venturi

Mondeo 2001 (10.2000-02.2007)

Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel - Fuel Metering Valve Mondeo 2001 (10/2000-02/2007)
Removal and Installation

General Equipment
Worldwide Diagnostic System (WDS)
Pneumatic vacuum 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.
WARNING:
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:
WARNING:Do not carry out any repairs to the fuel injection system with the engine running. The fuel pressure within the system can be as high as 1600 bar. Failure to follow this instruction may result in personal injury.
WARNING:
WARNING:Do not carry out any repairs to the fuel injection system without checking that the fuel pressure has dropped to zero and that the fuel temperature has either reached ambient temperature or is below 30ºC, whichever is the greater. Failure to follow these instructions may result in personal injury.
WARNING:
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:
CAUTION:Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfunction.
CAUTION:
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 matter ingress to the fuel injection system.
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.
All vehicles
  1. Using datalogger in WDS, check that the fuel pressure has dropped to zero and that the fuel temperature has either reached ambient temperature or is below 30°C, whichever is greater.
  1. Disconnect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

  1. Remove the engine upper cover.
    1. Remove the oil level indicator.
Vehicles built 07/2002 onwards
  1. Remove the exhaust gas recirculation (EGR) cooler to EGR valve tube.
    For additional information, refer to: Exhaust Gas Recirculation (EGR) Cooler to EGR Valve Tube (303-08C Engine Emission Control - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
All vehicles
  1. CAUTION:
    CAUTION:The generator must be protected from contamination. Failure to follow this instruction may cause premature failure of the generator.
    Protect the generator with lint-free material to prevent contamination.
  1. CAUTION:
    CAUTION:Protect the fuel metering valve and fuel temperature sensor electrical connectors to prevent contamination with the cleaning fluid.
    Clean the fuel pump and surrounding areas.
    For additional information, refer to: Fuel Injection Component Cleaning (303-04E Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, General Procedures).

  1. Disconnect the fuel metering valve and fuel temperature sensor electrical connectors.
  1. Using the Pneumatic vacuum gun, vacuum foreign material from the area around the fuel metering valve.

  1. Remove the fuel metering valve.
    • Install a new blanking plug to the open port of the fuel pump.

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.
WARNING:
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.
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.
CAUTION:
CAUTION:Make sure the workshop area in which the vehicle is being worked on is as clean and dust free as possible. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfunction.
CAUTION:
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 matter ingress to the fuel injection system.
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.
NOTE:
NOTE:Install a new fuel metering valve and O-ring seal.
  1. Remove and discard the blanking plug from the fuel pump.
  1. Using the Pneumatic vacuum gun, vacuum foreign material from the fuel pump open port.
  1. Using a suitable multipurpose lubricant spray, lubricate the O-ring seal.

  1. CAUTION:
    CAUTION:The fuel metering valve must be installed correctly into the fuel pump so that the mating faces are in contact with each other. Failure to follow this instruction may result in damage to the fuel metering valve.
    Install the fuel metering valve and O-ring seal.
    • Install the fuel metering valve retaining bolts finger tight.

  1. CAUTION:
    CAUTION:The fuel metering valve retaining bolts must be tightened in the following stages. Failure to follow this instruction may result in damage to the fuel metering valve.
    Tighten the fuel metering valve retaining bolts in two stages.
    • Stage 1: 2.5 Nm.
    • Stage 2: 5.5 Nm

  1. Connect the fuel metering valve and fuel temperature sensor electrical connectors.
  1. Remove the lint-free material protecting the generator.
Vehicles built 07/2002 onwards
  1. Install the exhaust gas recirculation (EGR) cooler to EGR valve tube.
    For additional information, refer to: Exhaust Gas Recirculation (EGR) Cooler to EGR Valve Tube (303-08C Engine Emission Control - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
All vehicles
  1. Install the engine upper cover.
    1. Install the oil level indicator.
  1. Connect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Initialize the door window motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

303-04E Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma) Diesel|Specifications > < Fuel Return Line Venturi