DIY Diesel fuel filter change Mondeo 2007-2014

[rondeo]

DIESEL FUEL FILTER CHANGE Mondeo TDCi 2007-2014

These notes were written for my own use and amusement, maybe someone will
find them useful. In any case its just how I have done it, no problems.

WARNING:

After changing the diesel filter the engine should start normally, ie at once,
and keep running.
If you get too much air in the fuel lines and attempt to start the engine for too long
the HP fuel pump might be damaged by lack of lubrication. Not to mention stressing the battery.

Get the fuel line connectors plugged smartly after disconnecting them.
No fuel coming out isn't a sign of no air getting in, as the lines may siphon,
drawing air in.
A problem might be getting/making nice fitting plugs, with those
it's easy. Without proper plugs you can't do it this way.



REQUIRED EQUIPMENT:

One smooth cylindrical plug 9.7mm diameter (3/8")
made of stainless steel, aluminium, brass or diesel resistant plastic
(I use acetal plastic from a plastics supplier and turned on a lathe).
Another plug of the same smoothness maybe 11.5mm (29/64) or (7/16) 11.11mm
(I can't remember which plug I used. I made three. I'll try to fix this in 8000km.)
Maybe a diesel fuel specialist would have some plugs. This could be a problem.
A rubber bulb fuel priming pump and suitable PVC hose.
I got a bulb from a marine supplies shop (BCF).
I found the female connector with the pump was the right size.
The main thing is not to damage the connector 'o' rings or get dirt in the lines.
Figure out how the connectors work and don't force anything.
Don't use jacks anywhere except at the designated points on the sill.

PROCEDURE

Remove the electrical connector from the filter housing.
Remove fuel inlet (smaller pipe) and immediately plug the female connector.
Remove fuel outlet (larger pipe) and immediately plug the female connector.
Drain diesel from filter housing using the drain plug.
Remove the filter housing from the bracket on the vehicle and replace filter.
Install the filter housing to the bracket on the vehicle.
Connect the outlet of a rubber bulb primer to the inlet on the filter housing.
Prime the filter with clean diesel until fuel starts flowing at the outlet with no bubbles.
Remove plugs one at a time and install both fuel line connectors,
making sure everything is clean.
Return unused clean diesel to the tank using the Ford adapter funnel.
Store the bits and pieces in a plastic storage container.
Maybe light the woodheater with the remaining fuel.