Ford Workshop Service and Repair Manuals

System components

A Bosch common rail diesel injection system is used on the 1.6L Duratorq TDCi (DV6) engine.

The fuel system consists of the following components:

• Fuel filter with diesel fuel preheating
• Fuel pump with integrated fuel transfer pump and fuel metering valve
• High-pressure fuel lines
• Common rail
• Fuel pressure sensor on the common rail
• Solenoid valve controlled injector valve
• Fuel return lines

Fuel pump

The fuel pump is driven by the timing belt. The fuel transfer pump is driven by the fuel pump drive shaft.

The fuel pump has three pumping elements with 120° offset (displacement pumps).

The fuel metering valve is located in the supply duct between the fuel transfer pump and the fuel pump, and meters the quantity of fuel which is to be delivered into the high-pressure chamber in accordance with the current operating status of the engine.

Any surplus fuel is returned to the fuel tank via the fuel return.

Common rail

NOTE: The fuel pressure sensor must not be dismantled from the common rail.

The fuel displaced by the fuel pump is guided through a short fuel line to the common rail.

The common rail is made of forged steel. It stores the fuel under high pressure and dampens any additional fluctuations in pressure.

The common rail is bolted directly onto the cylinder block by means of two retaining bolts.

The fuel system pressure is measured by the fuel pressure sensor. The fuel pressure sensor converts the fuel system pressure into a voltage signal. This voltage signal is used by the Powertrain Control Module (PCM) as an input signal to calculate the injection quantity.

High-pressure fuel lines

NOTE: The bending radii must not be altered.

NOTE: In order to avoid leaks, new high-pressure fuel lines must be installed whenever they are undone.

The high-pressure fuel lines connect the common rail to the fuel pump and the injectors.

All high-pressure fuel lines between the common rail and the injectors have the same length and are matched to the system.

Fuel injectors

NOTE: The copper sealing rings must not be reused.

NOTE: Refer to the current service literature for the exact details on correct installation of the shaft seals and the plastic washers.

The injectors are actuated directly by the PCM.

The injectors are secured by means of the fixing pieces, which are each attached via two nuts to the upper part of the cylinder head.

The fuel return lines are secured via clips on the upper side of the injectors.

When the injectors are installed the connections of the high-pressure fuel lines must point towards the valve cover.

The seal to the upper part of the cylinder head is provided by means of a radial oil seal and a plastic washer, which are inserted into the upper part of the cylinder head using a special tool.

Fuel filter

The fuel filter is attached directly to the cylinder head via a bracket and is equipped with an electric fuel pre-heating system.

The fuel lines are each secured by means of a quick-release coupling to the connections.

The fuel lines are colour coded, with white for the supply from the fuel tank and red for the outlet to the fuel pump.

The water separator must be drained using the drain plug (2) on a regular basis in accordance with the maintenance instructions.