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Fuel Pump > < Fuel Rail

Mondeo 2007.5 (02.2007-)

Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel - Fuel Injectors Mondeo 2007.5 (02/2007-)
Removal and Installation

Special Tool(s)
310-110A
Hand Pressure Pump with Adapter Kit
General Equipment
Flat-bladed screwdriver
Fluid container
Long nose pliers

Removal

WARNING:
WARNING:Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General Information, Description and Operation).
  1. Remove the valve cover.
    Refer to: Valve Cover (303-01E Engine - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).

  1. Clean the fuel injectors, high-pressure fuel supply lines and surrounding areas.
    Refer to: Fuel Injection Component Cleaning (303-04D Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel, General Procedures).

  1. CAUTION:
    CAUTION:Use an open-ended wrench to prevent the component from turning.
    CAUTION:
    CAUTION:Make sure that the fuel line remains in contact at both ends until both unions nuts have been unscrewed and the area around the joints thoroughly cleaned.
    CAUTION:
    CAUTION:Vacuum any foreign material from the fuel pump and fuel rail unions before sealing the unions with blanking caps.
    CAUTION:
    CAUTION:Make sure that all openings are sealed. Use new blanking caps.
    • Discard the the high-pressure fuel supply lines.
    • Discard the fuel injector sealing washers.

Installation
  1. NOTE:
    NOTE:Make sure that new components are installed.
    Discard the blanking caps.
    Torque:
    Stage 1:
    5 Nm
    Stage 2:
    90°

  1. General Equipment: Long nose pliers
    General Equipment: Flat-bladed screwdriver

  1. Loosen the bolts.

  1. NOTE:
    NOTE:Make sure that new components are installed.
    NOTE:
    NOTE:Only tighten the union nuts finger tight at this stage.
    Discard the blanking caps.

  1. Torque: 24 Nm

  1. CAUTION:
    CAUTION:Use an open-ended wrench to prevent the component from turning.
    Tighten in the sequence shown.
    Torque: 25 Nm

  1. Tighten in the sequence shown.
    Torque: 38 Nm
  1. Install the valve cover.
    Refer to: Valve Cover (303-01E Engine - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).

  1. Refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Using a suitable length of fuel resistant tube.
    General Equipment: Fluid container

  1. Special Tool(s): 310-110A

  1. Loosen the fuel filter bleed screw (special tool shown removed for clarity).
  1. Operate the hand pressure pump at least 30 times.

  1. Tighten the fuel filter bleed screw finger tight (special tool shown removed for clarity).

  1. Remove the length of fuel resistant tube and fluid container (special tool shown removed for clarity).
    General Equipment: Fluid container
  1. WARNING:
    WARNING:be prepared to collect escaping fuel.
    Operate the hand pressure pump special tool adapter until the fuel filter is full and the special tool becomes firm.
  1. CAUTION:
    CAUTION:The starter motor operation must not exceed 10 seconds at a time. After 10 seconds turn the ignition switch to position 0 and allow the starter motor to cool for 30 seconds before operating the starter motor again.
    Start the engine and allow it to idle until it reaches normal operating temperature.
  1. Stop the engine.

  1. Special Tool(s): 310-110A

  1. Refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
    Torque: 9 Nm

Fuel Pump > < Fuel Rail