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Fuel Return Line Venturi > < Fuel Injectors

Transit 2000.5 (01.2000-05.2006)

Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel - Fuel Pump Transit 2000.5 (01/2000-05/2006)
Removal and Installation

Special Tool(s)

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
Pneumatic vacuum gun
Worldwide Diagnostic System (WDS)

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.
CAUTION:
CAUTION:Do not disassemble or clean inside the fuel pump, even with an ultrasonic cleaner. Always install a new fuel pump when required.
  1. Using datalogger in WDS, check that the fuel pressure has dropped to zero and that the fuel temperature has reached ambient temperature or is below 30º C, whichever is the greater.

  1. CAUTION:
    CAUTION:Make sure that the windshield wiper motor is in the park position.
    Remove the windshield wiper arms.

  1. Remove the cowl panel upper retaining screws.
    • Remove the screw covers.
  1. Raise the hood.

  1. Remove the hood seal.

  1. Detach the heatshield from the water drain panel.

  1. NOTE:
    NOTE:The windshield washer hose is routed through the body panel.
    Remove the cowl panel.
    1. Remove the lower retaining screws.
    1. Detach the windshield washer hose.
    1. Detach the clips.

  1. Remove the water drain pipe retaining clips.

  1. Remove the A-pillar exterior trim panels lower retaining screws.

  1. Remove the windshield wiper motor bracket retaining bolt.

  1. Remove the water drain panel.
  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 accessory drive belt.
    For additional information, refer to: Accessory Drive Belt - 2.4L Duratorq-TDCi (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-TDCi (Puma) Diesel (303-08 Engine Emission Control, Removal and Installation).

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

  1. NOTE:
    NOTE:Turn the engine in the normal direction of rotation only.
    Turn the engine until the fuel pump sprocket timing hole is at the 1 o'clock position.

  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. Detach the camshaft position (CMP) sensor wiring harness from the intake manifold.

  1. Remove the intake manifold.

  1. Disconnect the fuel metering valve and fuel temperature sensor electrical connectors and protect them with lint-free material to prevent contamination from the cleaning fluid.
  1. Clean the fuel pump, high-pressure fuel supply line and surrounding areas.
    For additional information, refer to: Fuel Injection Component Cleaning (303-04F Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel, General Procedures).

  1. Disconnect the fuel injector to fuel pump and fuel pump fuel supply line quick release couplings.
    For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).
    • Install blanking plugs to the fuel pump and fuel line male and female connectors.

  1. Disconnect the fuel pump fuel supply line quick release coupling.
    For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).
    • Install blanking plugs to the fuel pump fuel supply line male and female connectors.

  1. CAUTION:
    CAUTION:Make sure that the tool used to loosen the high-pressure fuel supply line union is used at the top of the union as this is where there is most material. Failure to follow this instruction may result in damage to the union.
    Detach the high-pressure fuel supply line from the fuel pump.
  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel pump and the fuel rail until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply line and the fuel pump.

  1. CAUTION:
    CAUTION:Make sure that the tool used to loosen the high-pressure fuel supply line union is used at the top of the union as this is where there is most material. Failure to follow this instruction may result in damage to the union.
    Remove and discard the high-pressure fuel supply line.
  1. Using the pneumatic vacuum gun, vacuum foreign material from the fuel pump and the fuel rail.
  1. Install blanking caps to the open threaded ports on the fuel pump and the fuel rail.

  1. Remove the fuel pump support bracket.
    • Detach the knock sensor electrical connector from the fuel pump support bracket.
    • Remove the fuel pump support bracket retaining bolts.

  1. Remove the fuel pump.

  1. Remove the fuel pump fuel supply line from 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:Do not disassemble or clean inside the fuel pump, even with an ultrasonic cleaner. Always install a new fuel pump when required.
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.
NOTE:
NOTE:Install a new fuel pump gasket.
NOTE:
NOTE:Install a new high-pressure fuel supply line.
  1. Install the fuel pump fuel supply line to the fuel pump.
  1. NOTE:
    NOTE:Apply a small bead of loctite 572 to the fuel pump retaining bolts.
    NOTE:
    NOTE:Install a new fuel pump gasket.
    Install the fuel pump.

  1. Install the fuel pump support bracket.
    1. Install the fuel pump support bracket retaining bolts finger tight.
    1. Attach the knock sensor electrical connector to the fuel pump support bracket.

  1. Install the fuel pump sprocket retaining bolts.

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

  1. Remove the special tool.

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

  1. Tighten the fuel pump support bracket retaining bolts.
  1. CAUTION:
    CAUTION:Do not allow the unions to hit the olive ends of the high-pressure fuel supply line as this may damage the ends of the line and allow foreign matter to enter the fuel injection system.
    Position the new high-pressure fuel supply line as near to the final installation position as possible and then remove and discard the blanking plugs from the high-pressure fuel supply line.
  1. Remove and discard the blanking plugs from the fuel pump and fuel rail threaded ports.

  1. CAUTION:
    CAUTION:Do not tighten the high-pressure fuel supply line union at this stage.
    CAUTION:
    CAUTION:Maintain pressure on the high-pressure fuel supply line to keep the olive in contact with the fuel pump cone while installing the union. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    Install the high-pressure fuel supply line to the fuel pump union finger tight.

  1. CAUTION:
    CAUTION:Do not tighten the high-pressure fuel supply line union at this stage.
    CAUTION:
    CAUTION:Maintain pressure on the high-pressure fuel supply line to keep the olive in contact with the fuel rail cone while installing the union. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    Install the high-pressure fuel supply line to fuel rail finger tight.

  1. CAUTION:
    CAUTION:Make sure the tool used to tighten the high-pressure fuel supply line union is used at the top of the union as this is where there is most material. Failure to follow this instruction may result in damage to the union.
    CAUTION:
    CAUTION:Make sure the tool used to tighten the high-pressure fuel supply line union does not come into contact with the inlet metering valve while tightening the high-pressure fuel supply line union. Failure to follow this instruction may result in fuel leaking from the union.
    Tighten the high-pressure fuel supply line at the fuel pump.

  1. CAUTION:
    CAUTION:Make sure the tool used to tighten the high-pressure fuel supply line union is used at the top of the union as this is where there is most material. Failure to follow this instruction may result in damage to the union.
    Tighten the high-pressure fuel supply line at the fuel rail.
  1. Remove and discard the blanking caps from the fuel pump and fuel return line.

  1. Connect the fuel pump fuel return line quick release coupling.
    For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).
  1. Remove and discard the blanking caps from the fuel injector to fuel pump fuel pump fuel supply line and the fuel pump.
  1. Connect the fuel injector to fuel pump and fuel pump fuel supply line quick release couplings.
    For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).

  1. Connect the fuel metering valve and fuel temperature sensor electrical connectors.

  1. Install the intake manifold.

  1. Attach the CMP wiring harness to the intake manifold.
  1. Install the EGR valve.
    For additional information, refer to: Exhaust Gas Recirculation (EGR) Valve - 2.4L Duratorq-TDCi (Puma) Diesel (303-08 Engine Emission Control, 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).

  1. Install the water drain panel.

  1. Install the windshield wiper motor bracket retaining bolt.

  1. Install the A-pillar exterior trim panels lower retaining screws.

  1. Install the water drain pipe retaining clips.

  1. NOTE:
    NOTE:The windshield washer hose is routed through the body panel.
    Install the cowl panel.
    1. Install the lower retaining screws.
    1. Attach the windshield washer hose.
    1. Attach the clips.

  1. Attach the heatshield to the water drain panel.

  1. Install the hood seal.
  1. Lower the hood.

  1. Install the cowl panel upper retaining screws.
    • Install the screw covers.

  1. Install the windshield wiper arms.
  1. Install a new fuel filter.
    For additional information, refer to: Fuel Filter - Vehicles With: Common Rail Fuel Injection (310-01A Fuel Tank and Lines, Removal and Installation).

Fuel Return Line Venturi > < Fuel Injectors