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Fuel Injection Timing Solenoid > < Fuel Injection Pump - 75 PS-90 PS

Transit 2000.5 (01.2000-05.2006)

Fuel Charging and Controls - 2.4L Duratorq-Di (Puma) Diesel - Fuel Injection Pump—120 PS Transit 2000.5 (01/2000-05/2006)
Removal and Installation

Special Tool(s)

Timing Tool, Crankshaft TDC

303-675 (21-234)

Remover/Installer, Crankshaft Oil Seal

303-679 (21-238)

Locking Tool, Fuel Injection Pump Sprocket

303-1151

Socket, Fuel Injection Pump

310-083 (23-057)
General Equipment
Dowel with a diameter of 6 mm and a length of 65 mm
Screwdriver

Removal

  1. 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.
    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.
    Remove the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt - 2.4L Duratorq-Di (Puma) Diesel (303-05 Accessory Drive, Removal and Installation).
  1. Remove the exhaust gas recirculation (EGR) valve.
    For additional information, refer to: Exhaust Gas Recirculation (EGR) Valve - 2.4L Duratorq-Di (Puma) Diesel (303-08 Engine Emission Control, Removal and Installation).

  1. Disconnect the cylinder head temperature (CHT) sensor electrical connector.

  1. Remove the engine oil filler pipe.
  1. Remove the intake manifold.
    For additional information, refer to: Intake Manifold - Vehicles Built Up To: 04/2003, Vehicles Without: Common Rail Fuel Injection (303-01A Engine - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).

  1. Disconnect the high-pressure fuel supply lines from the fuel injectors.
  1. NOTE:
    NOTE:The starter motor must be removed in order to allow access to the high-pressure fuel supply line unions at the fuel injection pump.
    Remove the starter motor.
    For additional information, refer to: Starter Motor - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (303-06 Starting System, Removal and Installation).

  1. Disconnect the high-pressure fuel supply lines from the fuel injection pump.
  1. Lower the vehicle.

  1. Remove the high-pressure fuel supply line support bracket to high pressure fuel supply line retaining nuts.

  1. Remove the high-pressure fuel supply line support bracket to cylinder head bolt.

  1. Remove the high-pressure fuel supply line support bracket.

  1. Remove the high-pressure fuel supply lines.
    • Discard the high-pressure fuel supply lines.

  1. Disconnect the fuel injector return line.
    For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).

  1. Using the special tool, remove the fuel injection pump sprocket access cover.
    • Discard the sprocket access cover.

  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Turn the engine until the fuel injection pump sprocket timing hole is in the 12 o'clock position.
  1. Remove the crankshaft position (CKP) sensor.
    For additional information, refer to: Crankshaft Position (CKP) Sensor - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (303-14 Electronic Engine Controls, Removal and Installation).

  1. CAUTION:
    CAUTION:Do not turn the engine when the special tool is fully located into the flywheel. Failure to follow this instruction will cause damage to the CKP sensor hole.
    NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Turn the engine to 50 degrees before top dead center (TDC) and insert the special tool through the CKP sensor hole.

  1. Using the special tool, support the fuel pump sprocket.

  1. NOTE:
    NOTE:Access the fuel pump retaining bolts through the holes provided in the special tool 303-1151 and fuel pump sprocket. The fuel pump retaining bolts cannot be completely removed.
    Using the special tool, remove the fuel pump retaining bolts.

  1. Remove the fuel pump sprocket retaining bolts.

  1. Disconnect the fuel injection pump control unit electrical connector.
    • Slide out the locking tang.

  1. Disconnect the fuel supply and return lines from the fuel injection pump.
    For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Remove the fuel injection pump support bracket to cylinder block bolts (fuel injection pump shown removed and bracket shown from above for clarity).

  1. Remove the fuel injection pump support bracket to fuel injection pump bolts (bracket shown from above for clarity).
  1. Lower the vehicle.
  1. Remove the fuel injection pump and support bracket.
    • Discard the fuel injection pump gasket.

  1. Remove the fuel supply and return lines.
    • Discard the sealing washers.

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.
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.
NOTE:
NOTE:If a new fuel injection pump is to be installed, it must be configured to the powertrain control module (PCM) using WDS before the engine can be started.
  1. NOTE:
    NOTE:Install new fuel supply and return line sealing washers.
    Install the fuel supply and return lines.
  1. Install the two fuel injection pump gaskets.

  1. Using a suitable piece of dowel with a diameter of 6 mm and a length of 65 mm, reset the fuel injection pump timing.
    • Insert the dowel into the cut outs provided.
  1. Remove the suitable piece of dowel with a diameter of 6 mm and a length of 65 mm, from the fuel injection pump before installing the fuel injection pump to the cylinder block.
  1. NOTE:
    NOTE:Install a new fuel injection pump gasket.
    Install the fuel injection pump and fuel injection pump support bracket.
  1. Raise the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. NOTE:
    NOTE:Do not tighten the fuel injection pump support bracket to cylinder block bolts at this stage.
    Install the fuel injection pump support bracket to the cylinder block finger tight (bracket shown from above for clarity).

  1. NOTE:
    NOTE:Do not tighten the fuel injection pump support bracket to fuel injection pump bolts at this stage.
    Install the fuel injection pump support bracket to fuel injection pump bolts finger tight (bracket shown from above for clarity.)
  1. Lower the vehicle.

  1. NOTE:
    NOTE:Do not tighten the fuel injection pump sprocket retaining bolts at this stage.
    Install the fuel injection pump sprocket retaining bolts finger tight.

  1. Using the special tool, tighten the fuel pump retaining bolts.

  1. Remove the special tool.

  1. Install the fuel injection pump timing dowel to check the fuel injection pump timing.

  1. Tighten the fuel injection pump sprocket retaining bolts.
  1. Raise the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Tighten the fuel injection pump support bracket to fuel injection pump bolts (bracket shown from above for clarity).

  1. Tighten the fuel injection pump support bracket to cylinder block bolts (fuel injection pump shown removed and bracket shown from above for clarity).
  1. Lower the vehicle.

  1. Connect the fuel supply and return lines to the fuel injection pump.
    For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).

  1. Remove the fuel injection pump timing dowel.
  1. Using a suitable paint, mark the position of the crankshaft pulley in relation to the engine front cover.

  1. Remove the special tool from the CKP sensor hole.
  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Turn the engine two revolutions.

  1. CAUTION:
    CAUTION:Do not turn the engine when the special tool is fully located into the flywheel. Failure to follow this instruction will cause damage to the CKP sensor hole.
    NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Turn the engine to 50 degrees before TDC and insert the special tool through the CKP sensor hole.

  1. Insert the fuel injection pump timing dowel to check the fuel injection pump timing.

  1. CAUTION:
    CAUTION:Do not remove the fuel injection pump sprocket retaining bolts. Failure to follow this instruction may result in damage to the engine.
    Loosen the fuel injection pump sprocket retaining bolts.

  1. CAUTION:
    CAUTION:Do not make any adjustments to the timing chain tension using the fuel injection pump retaining bolts or nuts. Failure to follow this instruction may result in damage to the engine.
    Using a suitable screwdriver turn the fuel injection pump sprocket counterclockwise to tension the timing chain.

  1. Tighten the fuel injection pump sprocket retaining bolts.

  1. Remove the special tool from the CKP sensor hole.
  1. Install the CKP sensor.
    For additional information, refer to: Crankshaft Position (CKP) Sensor - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (303-14 Electronic Engine Controls, Removal and Installation).

  1. Remove the fuel injection pump timing dowel.

  1. Using the special tool, install the fuel injection pump sprocket access cover.
    • Install a new sprocket access cover.

  1. NOTE:
    NOTE:Make sure the fuel injection pump control unit electrical connector pins are clean.
    Connect the fuel injection pump control unit electrical connector.
    • Slide the locking tang into position.

  1. Connect the fuel injector return line.
    For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).

  1. NOTE:
    NOTE:Install new high-pressure fuel supply lines.
    Install the high-pressure fuel supply lines.

  1. NOTE:
    NOTE:Do not tighten the high-pressure fuel supply line unions at this stage.
    Connect the high-pressure fuel supply lines to the fuel injection pump.

  1. NOTE:
    NOTE:Do not tighten the high-pressure fuel supply line unions at this stage.
    Connect the high-pressure fuel supply lines to the fuel injectors.
  1. Raise the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Tighten the high-pressure fuel supply line unions to the fuel injection pump.
  1. Install the starter motor.
    For additional information, refer to: Starter Motor - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (303-06 Starting System, Removal and Installation).
  1. Install the intake manifold.
    For additional information, refer to: Intake Manifold - Vehicles Built Up To: 04/2003, Vehicles Without: Common Rail Fuel Injection (303-01A Engine - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).

  1. Install the engine oil filler pipe.

  1. Connect the CHT sensor electrical connector.
  1. Install the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt - 2.4L Duratorq-Di (Puma) Diesel (303-05 Accessory Drive, Removal and Installation).
  1. Install the EGR valve.
    For additional information, refer to: Exhaust Gas Recirculation (EGR) Valve - 2.4L Duratorq-Di (Puma) Diesel (303-08 Engine Emission Control, Removal and Installation).

  1. Disconnect the fuel injection pump to fuel filter return line from the fuel filter.
    For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).

  1. Using a suitable clear plastic tube and connectors, manufacture and install a bleed tube as shown.
    1. Connect the bleed tube to the return line from the fuel injection pump.
    1. Connect the bleed tube to the fuel filter.
    1. Place the bleed tube into a suitable container.
  1. Disconnect the fuel lift pump electrical connector.

  1. Using a 15A fused jumper wire, supply battery voltage and a good ground to the fuel lift pump electrical connector, to energize the fuel lift pump.
  1. When air-free fuel is being displaced into the container remove the bleed tube.

  1. Install a clear plastic tube as shown.
    1. Connect the clear plastic tube to the return line from the fuel injection pump.
    1. Connect the clear plastic tube to the fuel filter.
  1. NOTE:
    NOTE:If a new fuel injection pump has been installed and difficulties occur getting fuel through the high-pressure system, it must be configured to the PCM using WDS before the high-pressure fuel supply lines can be bled.
    Make sure the engine is still at 50 degrees before TDC by checking the paint marks.

  1. Using a 15A fused jumper wire, supply battery voltage and a good ground to the fuel lift pump electrical connector, to energize the fuel lift pump.

  1. NOTE:
    NOTE:Only one high-pressure fuel supply line will show signs of fuel escaping.
    Visually inspect the high-pressure fuel supply lines and tighten the high-pressure fuel supply line union which shows signs of fuel escaping.
  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Using the paint mark as a reference, slowly turn the engine through 180 degrees.
  1. Repeat the bleeding steps to bleed each of the three remaining high-pressure fuel supply lines.

  1. NOTE:
    NOTE:Make sure the two halves of the high-pressure fuel supply line support bracket are just loose enough to slide relative to each other.
    NOTE:
    NOTE:Do not tighten the high-pressure fuel supply line support bracket to high pressure fuel supply line nuts at this stage.
    Install the high-pressure fuel supply line support bracket to the high pressure fuel supply lines finger tight.

  1. NOTE:
    NOTE:Do not tighten the high-pressure fuel supply line support bracket to cylinder head bolt at this stage.
    Install the high-pressure fuel supply line support bracket to cylinder head bolt finger tight.

  1. Tighten the high-pressure fuel supply line support bracket to high pressure fuel supply line retaining nuts.

  1. Tighten the high-pressure fuel supply line support bracket to cylinder head bolt.

  1. Tighten the two halves of the high-pressure fuel supply line support bracket.
  1. Remove the jumper wire and connect the fuel lift pump electrical connector.
  1. Start the engine and gently raise the engine speed to 1000 rpm for approximately 2 to 3 minutes until no air is visible in the clear plastic pipe.
  1. Switch the engine off.
  1. Remove the clear plastic tube.

  1. Connect the fuel injection pump to fuel filter fuel return line to the fuel filter.
    For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).

Fuel Injection Timing Solenoid > < Fuel Injection Pump - 75 PS-90 PS