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.
NOTE: The fuel pressure and temperature sensors are an integral part of the fuel rail and cannot be replaced individually.
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. Remove the four high pressure fuel feed lines and discard them.
Make sure that both ends of the fuel line remain in contact until both union nuts have been loosened and the area around the connections has been thoroughly cleaned.
Plug all openings. Use new caps.
4.
5.
6.
7.
CAUTION: Plug all openings. Use new caps.
8.
9. 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.
10. 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 manifold. Tightening torque: 22 Nm
CAUTION: Clean area around element and remove foreign material from area.
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. Install the fuel pump bracket. Tightening torque: 8 Nm
7. Install the EGR pipeline. Tightening torque: 10 Nm
8. Install ventilation piping.
9. Connect the low pressure fuel return line.
10. Install new high pressure fuel lines, but do not fully tighten at this stage.
Clean the area around the element and remove foreign material from it. The high pressure fuel line fuel injectors must be installed in pairs. Nozzles 2 and 3, 1 and 4, respectively.
11. Tighten new high pressure fuel feed lines. Tightening torque: Stage 1: 22 Nm. Stage 2: 25 Nm
12. Install motor protection. Refer to Procedure: Engine Cover - 2.2L Duratorq - Td4 (501-05 Interior trim, Removal and installation).
13. Connect a wire of weight to the accumulator. Refer to procedure: Specifications (414-00 Charging system - General information, Specifications).
14. 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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