ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

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303-04C Fuel Charging and Controls - Turbocharger > < Fuel Rail - Vehicles Built From: 08-2006 75 PS-90 PS-110 PS

Transit.Tourneo Connect 2002.5 (06.2002-)

Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel - Fuel Return Line Venturi—1.8L Duratorq-TDCi (Lynx) Diesel Transit/Tourneo Connect 2002.5 (06/2002-)
Removal and Installation

General Equipment
Worldwide Diagnostic System (WDS)
Pneumatic vacuum gun

Removal

WARNING:
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:
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.
WARNING:
WARNING:Do not carry out any repairs to the fuel injection system with the engine running. The fuel pressure within the system can be as high as 1600 bar. Failure to follow this instruction may result in personal injury.
WARNING:
WARNING:Do not carry out any repairs to the fuel injection system without checking that the fuel pressure has dropped to zero and that the fuel temperature has either reached ambient temperature or is below 30º C. whichever is the greater. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:Wait at least one minute after the engine stops before commencing any repair to the fuel injection system. Failure to follow this instruction may result in personal injury.
CAUTION:
CAUTION:Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfunction.
CAUTION:
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 matter ingress to the fuel injection system.
CAUTION:
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. Always install blanking plugs to any open orifices or lines.
  1. Using datalogger in WDS, check that the fuel pressure has dropped to zero and that the fuel temperature has either reached ambient temperature or is below 30°C, whichever is greater.
  1. Disconnect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Remove the charge air cooler.
    For additional information, refer to: Charge Air Cooler - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel (75 PS/90 PS) (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. CAUTION:
    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.
  1. CAUTION:
    CAUTION:Protect the fuel metering valve and fuel temperature sensor electrical connectors to prevent contamination with the cleaning fluid.
    Clean the fuel pump and surrounding areas.
    For additional information, refer to: Fuel Injection Component Cleaning - Vehicles With: Common Rail Fuel Injection (303-04B Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel, General Procedures).

  1. Disconnect the fuel metering valve and fuel temperature sensor electrical connectors (high-pressure fuel supply line shown removed for clarity).

  1. Remove the fuel pump support bracket bolts (high-pressure fuel supply line shown removed for clarity).

  1. Disconnect the fuel pump to fuel filter fuel return line from the fuel return line venturi (high-pressure fuel supply line shown removed for clarity).
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
    • Install blanking plugs to the fuel pump fuel return line and the fuel return line venturi.

  1. Disconnect the fuel injector fuel return line from the fuel return line venturi.
    • Install blanking plugs to the fuel injector fuel return line and the fuel return line venturi.

  1. Remove the fuel pump shield from the fuel pump (fuel pump shown removed for clarity).
  1. Using the pneumatic vacuum gun, vacuum foreign material from the area around the fuel return line venturi.

  1. Remove the fuel return line venturi (fuel pump shown removed for clarity).
    • Install a blanking plug to the open port on the fuel pump.

Installation

WARNING:
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:
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:
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. Always install blanking plugs to any open orifices or lines.
CAUTION:
CAUTION:Make sure the workshop area in which the vehicle is being worked on is as clean and dust free as possible. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfunction.
CAUTION:
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 matter ingress to the fuel injection system.
CAUTION:
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. Always install blanking plugs to any open orifices or lines.
  1. Remove and discard the blanking plug from the fuel pump.
  1. Using the Pneumatic vacuum gun, vacuum foreign material from the fuel pump open port.
  1. Using a suitable multipurpose lubricant spray, lubricate the new fuel return line venturi O-ring seal.

  1. Install the fuel return line venturi (fuel pump shown removed for clarity).

  1. Install the fuel pump shield to the fuel pump (fuel pump shown removed for clarity).

  1. Remove the blanking plugs and connect the fuel injector fuel return line to the fuel return line venturi.
    • Discard the blanking plugs.

  1. Connect the fuel metering valve and fuel temperature sensor electrical connectors (high-pressure fuel supply line shown removed for clarity).

  1. Tighten the fuel pump support bracket bolts (high-pressure fuel supply line shown removed for clarity).

  1. Connect the fuel pump to fuel filter fuel return line.
  1. Remove the lint-free material protecting the generator.
  1. Install the charge air cooler.
    For additional information, refer to: Charge Air Cooler - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel (75 PS/90 PS) (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Connect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

303-04C Fuel Charging and Controls - Turbocharger > < Fuel Rail - Vehicles Built From: 08-2006 75 PS-90 PS-110 PS