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Fuel Injection Timing Solenoid > < Fuel Injection Pump

Transit 2000.5 (01.2000-05.2006)

Fuel Charging and Controls - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel - Fuel Injection One-Way Valve Transit 2000.5 (01/2000-05/2006)
Removal and Installation

Special Tool(s)

Hand Pressure Pump with Adapter Kit

310-110
General Equipment
Pneumatic vacuum gun
Small screwdriver

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.
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 the intake manifold.
    For additional information, refer to: Intake Manifold (303-01B Engine - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel, In-vehicle Repair).
  1. Using the pneumatic vacuum gun, clean the area around the high-pressure fuel supply lines.

  1. Disconnect the high-pressure fuel supply lines from the fuel injectors.
  1. Using the pneumatic vacuum gun, clean the area around the high-pressure fuel supply lines.

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

  1. Detach the engine wiring harness from the high-pressure fuel supply line support bracket.

  1. Remove the high-pressure fuel supply line support bracket.
    1. Remove the center retaining nut.
    1. Remove the outer retaining nuts.

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

  1. NOTE:
    NOTE:Fuel injection pump shown removed for clarity.
    Remove the fuel injection one-way valves.
    • Discard the fuel injection one-way valves.

  1. NOTE:
    NOTE:Fuel injection pump shown removed for clarity.
    Using a clean small screwdriver, carefully remove the sealing washers.
    • Discard the sealing washers.

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.
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. Lubricate the fuel injection one-way valves with Renap 220 oil (supplied in the parts kit).

  1. Position the sealing washers onto the end of the fuel injection one-way valves.

  1. NOTE:
    NOTE:Fuel injection pump shown removed for clarity.
    Install the fuel injection one-way valves.

  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 No. 1 and No. 2 fuel injectors.

  1. Connect the high-pressure fuel supply lines for No. 1 and No. 2 fuel injectors 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 No. 3 and No. 4 fuel injectors.

  1. Connect the high-pressure fuel supply lines for No. 3 and No. 4 fuel injectors to the fuel injection pump.
Left-hand drive vehicles
  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.
All vehicles
  1. Disconnect the fuel tank to fuel filter fuel supply line from the fuel filter.
    For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).

  1. Install the hand pressure pump special tool adapter to the fuel filter.
    • Rotate the fuel filter element locking ring counterclockwise.

  1. Install the hand pressure pump special tool adapter to the fuel tank to fuel filter fuel supply line.

  1. NOTE:
    NOTE:Make sure the hand primer special tool arrow indicating the direction of fuel flow is pointing towards the fuel filter.
    Install the hand pressure pump special tool to the hand pressure pump special tool adapters.

  1. Operate the hand pressure pump special tool adapter until fuel starts to flow through the fuel filter.
  1. Using a suitable paint, mark the position of the crankshaft pulley in relation to the engine front cover.

  1. NOTE:
    NOTE:Only one high-pressure fuel supply line will show signs of fuel escaping.
    Operate the fuel hand primer 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 Steps 16 and 17 to bleed the three remaining high-pressure fuel supply lines.

  1. Install the high-pressure fuel supply line support bracket.
    1. Install the outer retaining nuts.
    1. Install the center retaining nut.

  1. Attach the engine wiring harness to the high-pressure fuel supply line support bracket.
  1. Install the intake manifold.
    For additional information, refer to: Intake Manifold (303-01B Engine - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel, In-vehicle Repair).
All vehicles
  1. CAUTION:
    CAUTION:Do not operate the starter motor for longer than 10 seconds at a time. After 10 seconds, turn the ignition to position 0 and allow the starter motor to cool for 30 seconds before attempting to start the engine again.
    Start the engine and allow to idle until it reaches normal operating temperature.
  1. Switch the engine off.
Left-hand drive vehicles
  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.
All vehicles
  1. Remove the hand pressure pump special tool from the hand pressure pump special tool adapters.

  1. Remove the hand pressure pump special tool from the fuel tank to fuel filter fuel supply line.

  1. Remove the hand pressure pump special tool adapter from the fuel filter.

  1. Connect the fuel tank to fuel filter fuel fuel supply line to the fuel filter.
    For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).
Left-hand drive vehicles
  1. Remove the lint-free material from the generator.

Fuel Injection Timing Solenoid > < Fuel Injection Pump