Avoid open source of flame, sparks or flammable substances.
After stopping the engine, wait at least one minute before starting any repairs to the fuel injection system.
Clean the area around the element and remove foreign material from it. Plug all openings. Use new caps.
Bleed air from the fuel system by cranking the engine to bleed air from the system.
Removing
1. Disconnect the battery ground wire. Refer to procedure: Specifications (414-00 Charging system - General information, Specifications).
2. Remove the engine cover. Refer to Procedure: Engine Cover - 2.2L Duratorq - Td4 (501-05 Interior trim, Removal and installation).
3.
4.
5.
CAUTION: Plug all openings. Use new caps.
6.
7.
Clean the area around the element and remove foreign material from it. Plug all openings. Use new caps.
8. Release the high pressure fuel line between the fuel pump and the fuel manifold.
Clean the area around the element and remove foreign material from it. Plug all openings. Use new caps.
NOTE: Use an additional wrench to prevent the element from rotating.
9.
Clean the area around the element and remove foreign material from it. Plug all openings. Use new caps.
10.
11.
CAUTION: Discard seal as no longer needed.
NOTE: Make sure the fuel pump drive remains in place when the fuel pump is removed.
12. Remove the high pressure fuel line between the fuel pump and fuel manifold and discard it.
Installation
1. Install a new high pressure fuel line between the fuel pump and the fuel manifold.
CAUTION: Clean area around element and remove foreign material from area.
2. Install the fuel pump. Tightening torque: 22 Nm
Extreme cleanliness must be observed when handling this element. Install a new seal.
3. Connect the fuel pump to the high pressure fuel rail of the fuel rail, but do not fully tighten at this stage.
CAUTION: Clean the element of dirt and grease.
4. Tighten the high pressure fuel line. Tightening torque: Stage 1: 22 Nm. Stage 2: 25 Nm
5. Install the high pressure fuel line bolt. Tightening torque: 8 Nm
6. Connect the vacuum pipeline of the amplifier of brakes.
7. Install the fuel pump bracket. Tightening torque: 8 Nm
8. Install the EGR pipeline. Tightening torque: 10 Nm
9. Install ventilation piping.
10. Install motor protection. Refer to Procedure: Engine Cover - 2.2L Duratorq - Td4 (501-05 Interior trim, Removal and installation).
11. Connect a wire of weight to the accumulator. Refer to procedure: Specifications (414-00 Charging system - General information, Specifications).
12. Remove air from the fuel system.
CAUTION: Bleed air from the fuel system by cranking the engine to bleed air from the system.
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