| Removal and Installation Removal 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. 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. 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. All vehicles | | -
Clean the area around the fuel filter connections and fuel lines.
For additional information, refer to: Fuel Injection Component Cleaning (303-04F Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel, General Procedures).
| Left-hand drive vehicles | | -
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. | Vehicles built up to 11/2004 | | -
Remove and discard the fuel filter element. - Rotate the fuel filter element locking ring clockwise.
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Disconnect the fuel lines from the fuel filter.
For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).
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Remove the fuel filter bracket retaining nuts. | | | -
Remove the fuel filter service indicator. | Vehicles built 11/2004 onwards | | -
Remove and discard the fuel filter element. - Rotate the fuel filter clockwise.
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Disconnect the fuel lines from the fuel filter.
For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).
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Remove the fuel filter. - Remove the fuel filter retaining bolts.
- Remove the fuel filter crash shield.
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Remove the fuel filter service indicator. | Installation 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. 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. 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. Left-hand drive vehicles | | -
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. | Vehicles built up to 11/2004 | | -
Install the fuel filter service indicator. | | | -
Install the fuel filter to the fuel filter bracket. | | | -
Install the fuel filter and fuel filter bracket. | | | -
NOTE:Do not connect the fuel filter to fuel tank fuel supply line at this stage. Connect the fuel filter fuel lines.
For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).
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NOTE:Make sure that the fuel filter element and the fuel filter housing are correctly aligned. Loosely install the new fuel filter element. | | | -
NOTE:An audible click can be heard when the fuel filter element locking ring is correctly secured. Install the fuel filter element. - Rotate the fuel filter element locking ring counterclockwise.
| Vehicles built 11/2004 onwards | | -
CAUTION:Do not over tighten the fuel filter service indicator. The threads of the fuel filter service indicator are designed to jump back to the untorqued position if the fuel filter service indicator is over tightened. Failure to follow this instruction, will result in air ingress into the fuel system. Install the fuel filter service indicator. - Install the fuel filter service indicator finger tight.
- Rotate the fuel filter service indicator one quarter turn clockwise.
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NOTE:Do not connect the fuel filter to fuel tank fuel supply line at this stage. Connect the fuel filter fuel lines.
For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).
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NOTE:Make sure that the fuel filter element and fuel filter housing are correctly aligned. Loosely install the new fuel filter element. | | | -
Install the fuel filter element. - Rotate the fuel filter element counterclockwise.
| Left-hand drive vehicles | | -
Remove the lint-free material from the generator. | All Vehicles | | -
Bleed the fuel system.
For additional information, refer to: Fuel System Bleeding - Vehicles With: Common Rail Fuel Injection (310-00A Fuel System - General Information, General Procedures).
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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. | Left-hand drive vehicles | | -
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. | Vehicles built up to 11/2004 | | -
Connect the fuel tank to fuel filter fuel supply line to the fuel filter.
For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).
| Vehicles built 11/2004 onwards | | -
Connect the fuel tank to fuel filter fuel supply line to the fuel filter.
For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).
| Left-hand drive vehicles | | -
Remove the lint-free material from the generator. | |
