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Fuel Pressure Relief Valve > < Fuel Pump

Transit 2006.5 (04.2006-)

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:Wait for a minimum of 1 minute after the engine has stopped before carrying out any repair to the fuel injection system.
WARNING:
WARNING:Make sure that the fuel pressure has dropped to zero and that the fuel temperature is at ambient temperature.
CAUTION:
CAUTION:Extreme cleanliness must be exercised when handling these components.
Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel - Fuel Rail Transit 2006.5 (04/2006-)
Removal and Installation

General Equipment
Ford approved diagnostic tool
  1. General Equipment: Ford approved diagnostic tool
  1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Refer to: Intake Manifold (303-01C Engine - 2.4L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
  1. Refer to: Fuel Injection Component Cleaning (303-04D Fuel Charging and Controls - 3.2L Duratorq-TDCi (Puma) Diesel, 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.

  1. CAUTION:
    CAUTION:Make sure that all openings are sealed. Use new blanking caps.
    Refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  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.
    CAUTION:
    CAUTION:Make sure that all openings are sealed. Use new blanking caps.

Installation
  1. Torque:
    Stage 1:
    6 Nm
    Stage 2:
    23 Nm

  1. Torque:
    1: 10 Nm
    2, 3: 
    Stage 1:
    5 Nm
    Stage 2:
    35 Nm

  1. Torque:
    Stage 1:
    5 Nm
    Stage 2:
    35 Nm

  1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Refer to: Fuel Filter Element - Diesel (310-01 Fuel Tank and Lines, Removal and Installation).
  1. Refer to: Fuel System Bleeding (310-00 Fuel System - General Information, General Procedures).
  1. Carry out a Fuel System Leak Test using the following dignostic tool menu options: ToolBox/Powertrain/Service Functions
    General Equipment: Ford approved diagnostic tool

Fuel Pressure Relief Valve > < Fuel Pump