Ford Workshop Service and Repair Manuals

Hand Pressure Pump with adapter kit

310-110

Puller, Injection Pump Pulley

310-095 (23-067)

1. 

   WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel components. Highly flammable mixtures are always present and can ignite. Failure to follow these instructions may result in personal injury.
   

   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 fit blanking plugs to any open orifices or lines.
   Remove the timing belt. For additional information, refer to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01G Engine.

2. 

   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.

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

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

5. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

6. Remove the generator electrical connector cover.

7. Disconnect the generator electrical connectors.

8. Detach the air conditioning compressor and secure to one side.

9. Remove the generator.
   • Remove the lint free material from the generator.

10. Remove the generator mounting bracket.

11. Remove the fuel injection pump retaining bracket.
    • Remove the four bolts and one nut.

12. Lower the vehicle.

13. 

    NOTE:The fuel injection pump pulley is sealed to the fuel injection pump sprocket.
    Remove the fuel injection pump pulley retaining bolts.

14. Remove the injection pump pulley.
    • Insert the special tool into the bolt hole in the injection pump pulley.
    • Press the special tool towards the injection pump and at the same time screw in the stud of the special tool until the injection pump pulley comes free.

15. Remove and discard the fuel injection pump seal.

16. 

    NOTE:Fuel supply line connectors are white or identified by a white band. Fuel return line connectors are red or are identified by a red band.
    Disconnect the fuel supply and fuel return lines.
    1. Pull the clip to release the catch.
    2. Lift the connector to release the line.

17. Disconnect the fuel injection pump control unit electrical connector.
    1. Pull the clip to release.
    2. Remove the electrical connector.

18. Remove the fuel injection pump sprocket bolts.

19. 

    NOTE:Access the bolts through the holes provided. The fuel injection pump bolts cannot be removed completely.
    Remove the fuel injection pump.

20. Remove and discard the fuel injection pump gasket.

1. 

   WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel components. Highly flammable mixtures are always present and can ignite. Failure to follow these instructions may result in personal injury.
   

   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 fit blanking plugs to any open orifices or lines.
   

   NOTE:Install new fuel injection pipes.
   

   NOTE:Install a new fuel injection pump seal.
   

   NOTE:Install a new fuel injection pump gasket.
   

   NOTE:A new fuel injection pump may be supplied in a locked or unlocked position. This can be determined by inspecting the fuel injection pump driveshaft locking bolt. A locked fuel injection pump is fitted with a hexagon head bolt and supplied with a spacer. An unlocked fuel injection pump is fitted with an allen key bolt and no spacer. The fuel injection pump driveshaft must not be turned while locked.
   

   NOTE:Using a 6 mm drill bit, set the fuel injection pump to crankshaft timing.
   Install the fuel injection pump.

2. Install the fuel injection pump sprocket bolts.

3. Remove the drill bit.

4. 

   NOTE:The spacer is not required if the fuel injection pump is supplied in the unlocked position.
   Install the spacer provided between the hexagon head fuel injection pump driveshaft locking bolt and the fuel injection pump (if equipped).

5. Install a new fuel injection pump seal.

6. Connect the fuel injection pump control unit electrical connector.

7. Install the fuel pump supply line and fuel pump fuel return line.
   1. Rotate the clip to lock the catch.

8. 

   NOTE:Using loctite RTV 5910 seal the injection pump pulley to the injection pump sprocket.
   

   NOTE:Apply loctite 518 to the outer edge of the fuel injection pump pulley bolt holes.
   Install the fuel injection pump pulley.

9. Install the fuel injection pump retaining bracket.

10. Raise the vehicle.

11. Install the generator mounting bracket.

12. Install the generator.

13. Install the air conditioning compressor.

14. Install the generator electrical connectors.

15. Install the generator electrical connector cover.

16. Lower the vehicle.

17. 

    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.

18. 

    NOTE:Install new high-pressure fuel supply lines.
    

    NOTE:Do not tighten the high-pressure fuel supply lines at this stage.
    Connect the high-pressure fuel supply lines to the fuel injection pump.

19. 

    NOTE:Do not tighten the high-pressure fuel supply lines at this stage.
    Connect the high-pressure fuel supply lines to the fuel injectors.

20. 

    NOTE:Install new high-pressure fuel supply lines.
    Tighten the high-pressure fuel supply lines to the fuel injection pump.

21. 

    CAUTION:If supplied in the locked position the fuel injection pump must not be turned until the spacer is installed.
    Install the timing belt. For additional information, refer to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01G Engine.

22. Disconnect the fuel tank to fuel filter supply line and the fuel filter to fuel injection pump fuel supply line from the fuel filter. For additional information, refer to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information / 310-00C Fuel System - General Information.

23. Disconnect the fuel return line regulating valve from the fuel filter. For additional information, refer to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information / 310-00C Fuel System - General Information.
    • Detach the retaining clip.

24. Remove the fuel filter and fuel filter retaining bracket.
    1. Depressed the clip.
    2. Pull the fuel filter to remove.

25. 

    NOTE:Discard the fuel filter.
    Remove the fuel filter from the fuel filter retaining bracket.
    1. Remove the screw.
    2. Remove and discard the fuel filter.

26. 

    NOTE:Install a new fuel filter.
    

    NOTE:Make sure that you align the locating arrows on the fuel filter and fuel filter bracket.
    Install the fuel filter to the fuel filter retaining bracket.
    • Tighten the screw.

27. Connect the fuel return regulating valve and the fuel filter to fuel injection pump fuel supply line to the fuel filter. For additional information, refer to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information / 310-00C Fuel System - General Information.

28. 

    CAUTION:Make sure that the fuel filter connection is not damaged with the installation of the special tool, as this may cause air ingress to fuel lines.
    Install the hand pressure pump special tool adapter to the fuel filter.

29. 

    NOTE:Make sure that the hand primer 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 adapter on the fuel filter.

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

31. 

    NOTE:Make sure that the hand primer 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 adapter on the fuel tank to fuel filter fuel supply line.

32. Operate the fuel hand pressure pump special until fuel starts to flow through the fuel filter and fuel pump and the hand pressure pump special becomes firm.

33. 

    NOTE:If a new fuel injection pump has been installed and difficulties occur getting fuel through the high-pressure system, it must be configured to the PCM using WDS before the high-pressure fuel supply lines can be bled.
    Make sure the engine is still at TDC by checking the paint marks.

34. 

    NOTE:Only one high-pressure fuel supply line will show signs of fuel escaping.
    Operate the hand pressure pump special tool and tighten the high-pressure fuel supply line union which shows signs of fuel escaping.

35. 

    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.

36. Repeat steps 34 and 35 to bleed the three remaining high-pressure fuel supply lines.

37. Remove the lint-free material from the generator.

38. 

    CAUTION:Do not operate the starter motor for more than 10 seconds at a time. After 10 seconds, turn the ignition switch 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 it to idle until it reaches normal operating temperature.

39. Switch the engine off.

40. Remove the hand pressure pump special tool from the hand pressure pump special tool adapter on the fuel tank to fuel filter fuel supply line.

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

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

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

44. Connect the fuel tank to fuel filter fuel supply line to the fuel filter. For additional information, refer to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information / 310-00C Fuel System - General Information.