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Fuel Injection Timing Solenoid - 1.8L Duratorq-TDDi (Lynx) Diesel > < Fuel Injection Pump - 1.8L Duratorq-TDCi (Lynx) Diesel

Transit.Tourneo Connect 2002.5 (06.2002-)

Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel - Fuel Injection Supply Manifold—1.8L Duratorq-TDCi (Lynx) Diesel Transit/Tourneo Connect 2002.5 (06/2002-)
Removal and Installation

Special Tool(s)

Remover/Installer, Hose Clamp

303-397 (24-003)
General Equipment
Worldwide Diagnostic System (WDS)
Engine vacumm cleaner
WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:Do not carry out any repairs to the fuel injection system with the engine running. The fuel pressure within the system can be as high as 1600 bar. Failure to follow this instruction may result in personal injury.
WARNING:
WARNING:Do not carry out any repairs to the fuel injection system without checking that the fuel pressure has dropped to zero and that the fuel temperature has reached ambient temperature or is below 30°C, whichever is greater. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:Wait at least one minute after the engine stops before commencing any repair to the fuel injection system. Failure to follow this instruction may result in personal injury.
CAUTION:
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 install blanking plugs to any open orifices or lines.
CAUTION:
CAUTION:Do not disassemble or clean inside the fuel injection supply manifold, even with an ultrasonic cleaner. Always install a new fuel injection supply manifold when required.
CAUTION:
CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
  1. Using datalogger in WDS, check that the fuel pressure has dropped to zero and that the fuel temperature has either reached ambient temperature or is below 30°C, whichever is greater.
  1. Disconnect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Remove the charge air cooler. For additional information, refer to Section  303-12 Intake Air Distribution and Filtering.

  1. Using the special tool, detach the positive crankcase ventilation (PCV) hoses from the valve cover.
  1. CAUTION:
    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.
  1. CAUTION:
    CAUTION:Protect the fuel injector electrical connectors with lint-free material to prevent contamination from the cleaning fluid.
    Clean the fuel injectors, fuel injection supply manifold, high-pressure fuel supply lines and surrounding areas. For additional information, refer to Fuel Injection Component Cleaning in this Section.

7. Remove the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Camshaft position (CMP) sensor electrical connector
2
-
Fuel pressure sensor electrical connector
3
-
Fuel injection wiring harness retaining clip
4
-
Fuel injector electrical connectors

 
Item
Part Number
Description
5
-
High-pressure fuel supply line support bracket retaining nut
6
-
High-pressure fuel supply line support bracket retaining bolt
7
-
High-pressure fuel supply line support bracket
See Removal Detail
8
-
High-pressure fuel supply line and clamp
See Removal Detail
See Installation Detail
9
-
High-pressure fuel supply line clamp
See Removal Detail
See Installation Detail

 
Item
Part Number
Description
10
-
Fuel injector high-pressure fuel supply lines clamp
See Removal Detail
See Installation Detail
11
-
Fuel injector high-pressure fuel supply line
See Removal Detail
See Installation Detail
12
-
Fuel injector high-pressure fuel supply line
See Removal Detail
See Installation Detail
13
-
Fuel injector high-pressure fuel supply lines clamp
See Removal Detail
See Installation Detail
14
-
Fuel injector high-pressure fuel supply line
See Removal Detail
See Installation Detail
15
-
Fuel injector high-pressure fuel supply line
See Removal Detail
See Installation Detail
16
-
Fuel injection supply manifold
See Installation Detail

8. To install, reverse the removal procedure.

  1. Tighten the fuel system components in the following order:
    1. Tighten the fuel injector high-pressure fuel supply line to fuel injector unions.
    1. Tighten the fuel injector high-pressure fuel supply line to fuel injection supply manifold unions.
    1. Tighten the high-pressure fuel supply line to fuel pump union.
    1. Tighten the high-pressure fuel supply line to fuel injection supply manifold union.
    1. Tighten the fuel injection supply manifold retaining bolts.

Removal Details

Item 7 : High-pressure fuel supply line support bracket

  1. Clean the fuel pump, fuel injection supply manifold, high-pressure fuel supply line and surrounding areas.
    For additional information, refer to Fuel Injection Component Cleaning - Vehicles With: Common Rail Fuel Injection in this section.

Item 8 : High-pressure fuel supply line and clamp

CAUTION:
CAUTION:Make sure that the high-pressure fuel supply line remains in contact with the fuel pump and fuel injection supply manifold until all unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
  1. Detach the unions. Using the engine vacuum cleaner, vacuum foreign material from the high-pressure fuel supply line, the fuel pump and the fuel injection supply manifold prior to removing the high-pressure fuel supply line.
  1. Remove the high-pressure fuel supply line and clamp. Using the engine vacuum cleaner, vacuum foreign material from the fuel pump and the fuel injection supply manifold open threaded ports.
  1. Install new blanking caps to the open threaded ports on the fuel pump and the fuel injection supply manifold.

Item 9 : High-pressure fuel supply line clamp

NOTE:
NOTE:Make a note of the position of the high-pressure fuel supply line clamp.

Item 10 : Fuel injector high-pressure fuel supply lines clamp
Item 13 : Fuel injector high-pressure fuel supply lines clamp

NOTE:
NOTE:Make a note of the position of the fuel injection high-pressure fuel supply line clamps.

Item 11 : Fuel injector high-pressure fuel supply line
Item 12 : Fuel injector high-pressure fuel supply line
Item 14 : Fuel injector high-pressure fuel supply line
Item 15 : Fuel injector high-pressure fuel supply line

CAUTION:
CAUTION:Make sure that the fuel injector high-pressure fuel supply line remains in contact with the fuel injector and fuel injection supply manifold until all unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
  1. Detach the unions. Using the engine vacuum cleaner, vacuum foreign material from the high-pressure fuel supply line, the fuel injector and the fuel injection supply manifold prior to removing the fuel injector high-pressure fuel supply line.
  1. Remove the high-pressure fuel supply line and clamp. Using the engine vacuum cleaner, vacuum foreign material from the fuel injector and the fuel injection supply manifold open threaded ports.
  1. Install new blanking caps to the open threaded ports on the fuel injector and the fuel injection supply manifold.

Installation Details

Item 16 : Fuel injection supply manifold

NOTE:
NOTE:Do not tighten the fuel injection supply manifold retaining bolts at this stage.

Item 15 : Fuel injector high-pressure fuel supply line
Item 14 : Fuel injector high-pressure fuel supply line
Item 12 : Fuel injector high-pressure fuel supply line
Item 11 : Fuel injector high-pressure fuel supply line

CAUTION:
CAUTION:Do not allow the unions to hit the ends of the fuel injector high-pressure fuel supply line. Failure to follow this instruction may result in damage to the ends of the line and allow foreign material to enter the fuel injection system.
CAUTION:
CAUTION:Remove the blanking plugs from the fuel injector high-pressure fuel supply line at the last possible moment. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
NOTE:
NOTE:To aid identification of the fuel injector high-pressure fuel supply lines, the unions at the fuel injector end are etched with the cylinder number.
NOTE:
NOTE:Maintain pressure on the fuel injector high-pressure fuel supply line to keep the line in contact with the fuel injector cone, while installing the union.
NOTE:
NOTE:Do not tighten the fuel injector high-pressure fuel supply line unions at this stage.
  1. Lubricate the fuel injector high-pressure fuel supply line union threads with clean lubricant.
  1. Remove and discard the blanking caps from the fuel injector and the fuel injection supply manifold.

Item 13 : Fuel injector high-pressure fuel supply lines clamp
Item 10 : Fuel injector high-pressure fuel supply lines clamp

NOTE:
NOTE:Do not tighten the fuel injector high-pressure fuel supply lines clamp at this stage.
NOTE:
NOTE:Make sure the fuel injector high-pressure fuel supply lines clamp is installed in the same position as removed.

Item 9 : High-pressure fuel supply line clamp

NOTE:
NOTE:Make sure the high-pressure fuel supply line clamp is installed in the same position as removed.

Item 8 : High-pressure fuel supply line and clamp

CAUTION:
CAUTION:Do not allow the unions to hit the ends of the high-pressure fuel supply line. Failure to follow this instruction may result in damage to the ends of the line and allow foreign material to enter the fuel injection system.
CAUTION:
CAUTION:Remove the blanking plugs from the high-pressure fuel supply line at the last possible moment. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
NOTE:
NOTE:Maintain pressure on the high-pressure fuel supply line to keep the line in contact with the fuel pump and fuel injection supply manifold cone, while installing the union.
NOTE:
NOTE:Do not tighten the high-pressure fuel supply line unions at this stage.
  1. Lubricate the high-pressure fuel supply line union threads with clean lubricant.
  1. Remove and discard the blanking caps from the fuel pump and the fuel injection supply manifold.

Fuel Injection Timing Solenoid - 1.8L Duratorq-TDDi (Lynx) Diesel > < Fuel Injection Pump - 1.8L Duratorq-TDCi (Lynx) Diesel