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Transit 2006.5 (04.2006-)

Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel - Fuel Pump Transit 2006.5 (04/2006-)
Removal and Installation

General Equipment
Ford diagnostic equipment

Removal

WARNING:
WARNING:Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
WARNING:
WARNING:Make sure that the engine is switched off.
WARNING:
WARNING:Make sure that the fuel pressure has dropped to zero and that the fuel temperature is at ambient temperature.
WARNING:
WARNING:Wait for a minimum of 1 minute after the engine has stopped before commencing any repair to the fuel injection system.
NOTE:
NOTE:Removal steps in this procedure may contain installation details.
  1. Within the datalogger function, check that the fuel pressure has dropped to zero and that the fuel temperature has either reached ambient temperature or is below 30ºC whichever is the greater.
    General Equipment: Ford diagnostic equipment
  1. Disconnect the battery ground cable.
    Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Remove the air cleaner.
    Refer to: Air Cleaner - 2.2L Duratorq-TDCi (Puma) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).

  1. CAUTION:
    CAUTION:Make sure that all openings are sealed. Use new blanking caps.
    Vacuum foreign material from the low-pressure fuel supply line and fuel return line.
    Refer to: Fuel Injection Component Cleaning (303-04 Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, General Procedures).
    Refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. CAUTION:
    CAUTION:Make sure that the fuel line remains in contact at both ends until both unions nuts have been unscrewed and the area around the joints thoroughly cleaned.
    CAUTION:
    CAUTION:Make sure that all openings are sealed. Use new blanking caps.
    Vacuum foreign material from the high-pressure fuel supply line, the fuel pump and the fuel rail.
    Refer to: Fuel Injection Component Cleaning (303-04 Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, General Procedures).
  1. Discard the high-pressure fuel supply line.

Installation

  1. To install, reverse the removal procedure.

  1. Torque: 23 Nm
  1. Install a new fuel rail high-pressure fuel supply line.

  1. Tighten the fuel rail high-pressure fuel supply line unions in two stages.
    Torque:
    Fuel rail high-pressure fuel supply line unions 
    Stage 1:
    5 Nm
    Stage 2:
    35 Nm
    Fuel rail high-pressure fuel supply line bracket bolt 10 Nm
  1. Install a new fuel filter element.
    Refer to: Fuel Filter Element - 2.2L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).
  1. Carry out a Fuel System Leak Test using the following menu options: ToolBox/Powertrain/Service Functions
    General Equipment: Ford diagnostic equipment
  1. Carry out a Pump Learn procedure using the following menu options: ToolBox/Powertrain/Service Functions
    General Equipment: Ford diagnostic equipment
  1. Carry out the Pilot Correction Learn procedure using the following menu options: ToolBox/Powertrain/Service Functions
    General Equipment: Ford diagnostic equipment

Fuel Rail > < Fuel Injectors