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Fuel Injection One-Way Valve > < Fuel Injection Pump - 120 PS

Transit 2000.5 (01.2000-05.2006)

Fuel Charging and Controls - 2.4L Duratorq-Di (Puma) Diesel - Fuel Injection Timing Solenoid Transit 2000.5 (01/2000-05/2006)
Removal and Installation

General Equipment
Pneumatic vacuum gun
Heat gun
Blunt plastic tool
Cable-ties

Removal

All vehicles
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.
  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. 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).
NOTE:
NOTE:A small quantity of oil will be lost when the engine oil cooler is detached from the engine block.

  1. Detach the oil cooler.
    1. Disconnect the oil pressure sensor electrical connector.
    1. Remove the oil cooler and oil filter assembly retaining bolts.

        2. 1. Discard the oil cooler seal.
  1. Wrap the oil cooler and oil filter assembly in a suitable absorbent material.
  1. Secure the oil cooler and oil filter assembly to one side using a cable-tie.
Vehicles with 75 PS or 90 PS diesel engine
  1. Remove the fuel injection pump support bracket plate.

  1. Remove the fuel injection pump engine support bracket.
Vehicles with 115 PS, 120 PS or 125 PS diesel engine
  1. Remove the fuel injection pump support bracket to fuel injection pump retaining nuts.

  1. Remove the fuel injection pump support bracket.

  1. Remove the fuel injection pump backplate retaining bolt.
    • Allow the fuel injection timing solenoid wiring harness retaining clip to detach from the fuel injection pump.
NOTE:
NOTE:Do not allow the fuel injection timing solenoid wiring harness to become trapped by the fuel injection pump backplate retaining bolt.
  1. Install the fuel injection pump backplate retaining bolt.
All vehicles
  1. Using the pneumatic vacuum gun, clean the area around the fuel injection timing solenoid.

  1. Detach the fuel injection timing solenoid (vehicles with 75 PS or 90 PS engine shown, 115 PS, 120 PS or 125 PS similar).
    • Remove and discard the fuel injection timing solenoid retaining bolts.

  1. CAUTION:
    CAUTION:O-ring seals must only be removed from the fuel injection pump, using a blunt plastic tool. Failure to follow this instruction may result in damage to the fuel injection pump.
    Inspect the fuel injection timing solenoid to make sure both O-ring seals are still fitted. If the fuel injection timing solenoid O-ring seal(s) is missing from the fuel injection timing solenoid, the missing fuel injection timing solenoid O-ring seal(s) must be removed from the fuel injection pump using a suitable blunt plastic tool.

  1. Remove the fuel injection timing solenoid.
    • Cut the fuel injection timing solenoid wiring harness as close to the fuel injection timing solenoid as possible.
  1. Lower the vehicle.
Vehicles with 115 PS, 120 PS or 125 PS diesel engine
  1. Remove the fuel injection pump backplate retaining bolt.
    • Remove and discard the fuel injection timing solenoid wiring harness retaining clip.
    • Remove the fuel injection timing solenoid wiring harness from the fuel injection pump body.

  1. Install the fuel injection pump backplate retaining bolt.

Installation

All vehicles
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.

  1. CAUTION:
    CAUTION:Do not remove the fuel injection timing solenoid protective cover supplied with the new fuel injection timing solenoid at this stage. Failure to follow this instruction may result in failure of the fuel injection solenoid or fuel injection pump.
    Remove the fuel injection timing solenoid electrical connector.
    • Cut the new fuel injection timing solenoid wiring harness as close to the fuel injection timing solenoid electrical connector as possible.
    • Discard the fuel injection timing solenoid electrical connector.

  1. Secure the new fuel injection timing solenoid to the fuel injector high-pressure fuel supply line using a cable-tie.
    • Route the fuel injection timing solenoid wiring harness between the high-pressure fuel lines and the cylinder block.
  1. Lower the vehicle.
  1. Install the new fuel injection timing solenoid wiring harness protective cover supplied in the service kit over the fuel injection pump fuel injection timing solenoid wiring harness.

  1. NOTE:
    NOTE:The fuel injection timing solenoid wiring harness can be connected either way round and it will not affect the function of the new fuel injection timing solenoid.
    Connect the new fuel injection timing solenoid wiring harness.
    1. Route the wiring harness of the new fuel injection timing solenoid between the fuel injection pump and engine block.
    1. Connect the fuel injection timing solenoid wiring harness.

        2. 1. Trim the new fuel injection timing solenoid wiring harness and the fuel injection pump fuel injection timing solenoid wiring harness to produce staggered joints.

        2. Using the pink crimp electrical connectors, supplied in the service kit, join the new fuel injection timing solenoid wiring harness to the fuel injection pump fuel injection timing solenoid wiring harness.

        3. Using a heat gun, heat shrink the two electrical connectors to the fuel injection timing solenoid wiring harness.

    1. Position the fuel injection timing solenoid wiring harness protective cover over the wiring harness crimped connectors.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).
  1. Using the pneumatic vacuum gun, clean the fuel injection pump fuel injection timing solenoid bore.

  1. Install the fuel injection timing solenoid (vehicles with 75 PS or 90 PS engine shown, 115 PS, 120 PS or 125 PS similar).
    1. Remove and discard the fuel injection timing solenoid retaining tie-strap.
    1. Remove the fuel injection timing solenoid protective cover.
    1. Install new fuel injection timing solenoid retaining bolts.
Vehicles with 115 PS, 120 PS or 125 PS diesel engine
NOTE:
NOTE:No excess wiring harness must remain between the fuel injection timing solenoid and the fuel injection pump backplate retaining screw, after the wiring harness has been secured.
  1. Secure the fuel injection timing solenoid wiring harness to the fuel injection pump backplate retaining screw using a cable-tie.

  1. Install the fuel injection pump support bracket.
    • Install the fuel injection pump support bracket retaining bolts hand tight.

  1. Install the fuel injection pump support bracket to fuel injection pump retaining nuts.

  1. Tighten the fuel injection pump support bracket retaining bolts.
Vehicles with 75 PS or 90 PS diesel engine
  1. Install the fuel injection pump support bracket.
    • Install the fuel injection pump support bracket retaining bolts hand tight.

  1. Install the fuel injection pump support bracket plate. Tighten the fuel injection pump support bracket plate retaining bolts in the sequence shown.
    1. Tighten the fuel injection pump support bracket plate to fuel injection pump retaining bolts to 10 Nm.
    1. Tighten the fuel injection pump support bracket plate to fuel injection pump engine support bracket retaining bolts to 22 Nm.

  1. Tighten the fuel injection pump engine support bracket retaining bolts.
All vehicles
  1. Install the oil cooler and filter assembly.
    • Remove the absorbent material.
    • Remove the cable-tie.
    • Using a new oil seal, install the oil cooler and filter assembly retaining bolts.

  1. Connect the engine oil pressure sensor electrical connector.
  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. Lower the vehicle.
Vehicles with 115 PS, 120 PS or 125 PS diesel engine
  1. Disconnect the fuel injection pump electrical connector.
    • Slide out the locking tang.

  1. Install a cable-tie around the fuel injection pump backplate retaining bolt.

  1. Connect the fuel injection pump electrical connector.
    • Slide the locking tange into position.

  1. Using cable-ties, secure the fuel injection timing solenoid wiring harness.
    • Pull the excess fuel injection timing solenoid wiring harness from the back of the fuel injection pump and secure the wiring harness to the fuel injection pump backplate retaining bolt.
    • Make a loop with the remaining fuel injection timing solenoid wiring harness and using a cable-tie secure the wiring harness loop to the fuel injection shutoff solenoid wiring harness.
Vehicles with 75 PS or 90 PS diesel engine
CAUTION:
CAUTION:Secure the excess fuel injection timing solenoid wiring harness using a cable-tie. Failure to follow this instruction may result in the failure of the fuel injection timing solenoid wiring harness.

  1. Using a cable-tie, secure the fuel injection timing solenoid wiring harness.
    • Make a loop with the excess fuel injection timing solenoid wiring harness and using a cable-tie secure the loop.
All vehicles
  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. Check and top up the engine oil level.

Fuel Injection One-Way Valve > < Fuel Injection Pump - 120 PS