ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
Fuel Metering Valve - 1.8L Duratorq-TDCi (Lynx) Diesel (75 PS-90 PS) > < Fuel Injection Supply Manifold - 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 Timing Solenoid—1.8L Duratorq-TDDi (Lynx) Diesel Transit/Tourneo Connect 2002.5 (06/2002-)
Removal and Installation

General Equipment
Pneumatic vacuum gun
Heat gun
Blunt plastic tool
Cable-ties

Removal

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.
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.
  1. Remove the charge air cooler.
    For additional information, refer to: Charge Air Cooler - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel (75 PS/90 PS) (303-12 Intake Air Distribution and Filtering, Removal and Installation).

  1. Remove the fuel injection pump back plate and support bracket retaining bolts.
  1. Remove the generator.
    For additional information, refer to: Generator - 1.8L Duratorq-TDDi (Kent) Diesel/1.8L Duratorq-TDCi (Kent) Diesel (414-02, Removal and Installation).

  1. Remove the air conditioning A/C compressor support bracket (if equipped).

  1. Remove the generator support bracket.

  1. Detach the coolant transfer pipe.
    • Remove the coolant transfer pipe retaining bolts.

  1. Remove the fuel injection pump support bracket retaining bolts.

  1. Remove the fuel injection pump back plate and support bracket assembly.
    • Remove the fuel injection pump back plate retaining bolts.

  1. Detach the fuel injection timing solenoid.
    • Remove and discard the fuel injection timing solenoid retaining bolts.

  1. CAUTION:
    CAUTION:O-ring seals must only be removed from the fuel injection pump, using a blunt plastic tool. Failure to follow this instruction may result in damage to the fuel injection pump.
    Inspect the fuel injection timing solenoid to make sure both O-ring seals are still fitted. If the fuel injection timing solenoid O-ring seal(s) is missing from the fuel injection timing solenoid, the missing fuel injection timing solenoid O-ring seal(s) must be removed from the fuel injection pump using a suitable blunt plastic tool.

  1. Remove the fuel injection timing solenoid.
    • Cut the fuel injection timing solenoid wiring harness as close to the fuel injection timing solenoid as possible.
  1. Lower the vehicle.

Installation

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.
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.

  1. CAUTION:
    CAUTION:Do not remove the fuel injection timing solenoid protective cover supplied with the new fuel injection timing solenoid at this stage. Failure to follow this instruction may result in failure of the fuel injection solenoid or fuel injection pump.
    Remove the fuel injection timing solenoid electrical connector.
    • Cut the new fuel injection timing solenoid wiring harness as close to the fuel injection timing solenoid electrical connector as possible.
    • Discard the fuel injection timing solenoid electrical connector.

  1. Secure the new fuel injection timing solenoid to the fuel injector high-pressure fuel supply line using a cable-tie.
    • Route the fuel injection timing solenoid wiring harness between the high-pressure fuel lines and the cylinder block.
  1. Install the new fuel injection timing solenoid wiring harness protective cover supplied in the service kit over the fuel injection pump fuel injection timing solenoid wiring harness.

  1. NOTE:
    NOTE:The fuel injection timing solenoid wiring harness can be connected either way round and it will not affect the function of the new fuel injection timing solenoid.
    Connect the new fuel injection timing solenoid wiring harness.
    1. Route the wiring harness of the new fuel injection timing solenoid between the fuel injection pump and engine block.
    1. Connect the fuel injection timing solenoid wiring harness.

        2. 1. Trim the new fuel injection timing solenoid wiring harness and the fuel injection pump fuel injection timing solenoid wiring harness to produce staggered joints.

        2. Using the pink crimp electrical connectors, supplied in the service kit, join the new fuel injection timing solenoid wiring harness to the fuel injection pump fuel injection timing solenoid wiring harness.

        3. Using a heat gun, heat shrink the two electrical connectors to the fuel injection timing solenoid wiring harness.

    1. Position the fuel injection timing solenoid wiring harness protective cover over the wiring harness crimped connectors.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).
  1. Using the pneumatic vacuum gun, clean the fuel injection pump fuel injection timing solenoid bore.

  1. Install the fuel injection timing solenoid.
    1. Remove and discard the fuel injection timing solenoid retaining cable-tie.
    1. Remove the fuel injection timing solenoid protective cover.
    1. Install new fuel injection timing solenoid retaining bolts.

  1. Install the fuel injection pump back plate and support bracket assembly.
    • Install the fuel injection pump back plate retaining bolts hand tight.

  1. Install the fuel injection pump support bracket retaining bolts.

  1. Tighten the fuel injection pump back plate retaining bolts.

  1. Install the coolant transfer pipe retaining bolts.

  1. Install the generator support bracket.

  1. Install the A/C compressor support bracket (if equipped).
  1. Install the generator.
    For additional information, refer to: Generator - 1.8L Duratorq-TDDi (Kent) Diesel/1.8L Duratorq-TDCi (Kent) Diesel (414-02, Removal and Installation).

  1. Install the fuel injection pump back plate and support bracket retaining bolts.
CAUTION:
CAUTION:Secure the excess fuel injection timing solenoid wiring harness using a cable-tie. Failure to follow this instruction may result in the failure of the fuel injection timing solenoid wiring harness.

  1. Using a cable-tie, secure the fuel injection timing solenoid wiring harness.
    • Make a loop with the excess fuel injection timing solenoid wiring harness and using a cable-tie secure the loop.
  1. Install the charge air cooler.
    For additional information, refer to: Charge Air Cooler - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel (75 PS/90 PS) (303-12 Intake Air Distribution and Filtering, Removal and Installation).

Fuel Metering Valve - 1.8L Duratorq-TDCi (Lynx) Diesel (75 PS-90 PS) > < Fuel Injection Supply Manifold - 1.8L Duratorq-TDCi (Lynx) Diesel