Ford Workshop Service and Repair Manuals

A Siemens common rail diesel injection system is used on the 2.0L Duratorq TDCi (DW10) engine.

Within the fuel pump is an integral fuel transfer pump which delivers the fuel from the fuel tank to the fuel pump.

A fuel metering valve is located in the feed port to the high-pressure chamber of the fuel pump. The fuel metering valve varies the quantity of fuel supplied to the fuel pump elements, in accordance with driving conditions.

At high-pressure, the fuel is sent to the fuel rail and then to the fuel injectors ready for fuel injection. Depending on engine operating conditions, the fuel injection pressure varies between approximately. 350 bar and 1650 bar.

Fuel pressure is measured using a FRP sensor on the fuel rail. The FRP sensor converts the fuel system pressure into a voltage signal. This voltage signal acts as an input signal to the powertrain control module (PCM) for calculation of the correct fuel injection quantity.

The PCM calculates the time of fuel injection and the fuel injection quantity depending on various input variables.

The specified quantity of fuel is injected into the respective combustion chamber through the piezo-electrically actuated fuel injectors. In doing so, a pre-injection and a main injection occur each time.

The excess fuel is returned to the fuel tank through the fuel return line.

The fuel pressure regulator on the high-pressure outlet of the fuel pump regulates the fuel pressure and thereby also the pressure within the fuel rail.

Fuel pump

The fuel pump is attached to the cylinder head on the transmission side and is driven directly by the exhaust camshaft through a drive flange.

The fuel pump has three pump elements, each offset from each other by 120 degrees.

The fuel transfer pump is incorporated into the fuel pump and is located on the drive flange. The fuel transfer pump is a vane type pump.

The fuel metering valve is located in the feed port between the high-pressure pump elements and the fuel transfer pump. It is controlled by the PCM using pulse width modulation.

The high-pressure outlets of the three high-pressure pump elements are grouped together in a high-pressure connection.

The fuel pressure regulator is located on the high-pressure outlet to the fuel rail. The fuel pressure regulator operates electromagnetically and is actuated by the PCM.

Fuel rail

The fuel rail is made from forged steel and is attached directly to the cylinder block.

The high-pressure fuel is delivered through one high-pressure fuel supply line from the fuel pump to the fuel rail.

From the fuel rail, the high-pressure fuel is directed to four more high-pressure fuel supply lines for fuel injection delivery by the fuel injectors.

Fuel filter

The fuel filter is located above the fuel rail and is attached to the cylinder head by means of a bracket.

The fuel filter has an electric fuel heater which is located centrally on the fuel filter between the supply connection and the drain connection.

The fuel filter forms a single component with the housing and can only be renewed as a complete unit.

The fuel filter also has a drain plug. This must be drained regularly in accordance with maintenance instructions.

Fuel injectors

The fuel injectors are located centrally on the cylinder head upper section and are attached by means of clamps.

The guide bushes in the cylinder head lower section and the plastic guide bushes on the fuel injectors make sure that they are centred properly.

The fuel injectors are sealed off from the combustion chamber by means of a copper sealing washer located between the fuel injector and the cylinder head. A new sealing washer must be installed when servicing the fuel injectors.

The fuel return lines are attached to the top of the fuel injector and are connected in series.

Intake air shutoff throttle

The intake air shutoff throttle is located on the intake air side of the intake manifold.

The intake air shutoff throttle is electronically controlled by the PCM and is used to control vehicle characteristics while the engine is switched off. This will also prevent the engine being continuously fuelled by the engine oil after the ignition key has been turned to position 0. This is achieved by reducing the intake air through the intake manifold.