ford Workshop Repair Guides

Ford Workshop Manuals

< PREV PAGE NEXT PAGE >
Fuel Charging and Controls - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel - Fuel Injection Pump Transit 2000.5 (01/2000-05/2006)
Removal and Installation

Special Tool(s)

Timing Tool, Crankshaft TDC

303-675 (21-234)

Remover/Installer, Crankshaft Oil Seal

303-679 (21-238)

Locking Tool, Fuel Injection Pump Sprocket

303-1151

Socket, Fuel Injection Pump

310-083 (23-057)

Hand Pressure Pump with Adapter Kit

310-110

General Equipment
Dowel with a diameter of 6 mm and a length of 65 mm
Screwdriver

Removal

  1. 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.
    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.
    Remove the intake manifold.
    For additional information, refer to: Intake Manifold (303-01B Engine - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel, In-vehicle Repair).

  1. Using the special tool, remove the fuel injection pump sprocket access cover.
    • Discard the sprocket access cover.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Turn the engine until the fuel injection pump sprocket timing hole is in the 12 o'clock position.
  1. Lower the vehicle.
  1. Remove the crankshaft position (CKP) sensor.
    For additional information, refer to: Crankshaft Position (CKP) Sensor - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel (303-14 Electronic Engine Controls, Removal and Installation).

  1. CAUTION:
    CAUTION:Do not turn the engine when the special tool is fully located into the flywheel. Failure to follow this instruction will cause damage to the CKP sensor hole.
    NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Turn the engine to 50 degrees before top dead center (TDC) and insert the special tool through the CKP sensor hole.

  1. Disconnect the high-pressure fuel supply lines from the fuel injectors.
  1. NOTE:
    NOTE:The starter motor must be removed in order to allow access to the high-pressure fuel supply line unions at the fuel injection pump.
    Remove the starter motor.
    For additional information, refer to: Starter Motor - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel (303-06 Starting System, Removal and Installation).

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

  1. Detach the engine wiring harness from the high-pressure fuel supply line support bracket.

  1. Remove the high-pressure fuel supply line support bracket.
    1. Remove the center retaining nut.
    1. Remove the outer retaining nuts.

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

  1. Disconnect the fuel injection pump control unit electrical connector.
    • Slide out the locking tang.

  1. Disconnect the fuel supply and return lines from the fuel injection pump.
    For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).

  1. Using the special tool, support the fuel pump sprocket.

  1. NOTE:
    NOTE:Access the fuel pump retaining bolts through the holes provided in the special tool 303-1151 and fuel pump sprocket. The fuel pump retaining bolts cannot be completely removed.
    Using the special tool, remove the fuel pump retaining bolts.

  1. Remove the fuel pump sprocket retaining bolts.

  1. Remove the fuel injection pump support bracket to cylinder block bolts (fuel injection pump shown removed for clarity).

  1. Remove the fuel injection pump support bracket to fuel injection pump bolts and remove the fuel injection pump.
    • Discard the gasket.

  1. Remove the fuel supply and return lines.
    • Discard the sealing washers.

Installation

All Vehicles
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.
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.

  1. NOTE:
    NOTE:If a new fuel injection pump is to be installed, it must be configured to the powertrain control module (PCM) using WDS before the engine can be started.
    NOTE:
    NOTE:Install new sealing washers.
    Install the fuel supply and return lines.

  1. NOTE:
    NOTE:Do not tighten the fuel injection pump support bracket to cylinder block bolts at this stage.
    Install the fuel injection pump support bracket to the cylinder block finger tight.

  1. Using a suitable piece of dowel with a diameter of 6 mm and a length of 65 mm, reset the fuel injection pump timing.
    • Insert the dowel into the cut outs provided.
  1. Remove the suitable piece of dowel with a diameter of 6 mm and a length of 65 mm, from the fuel injection pump before installing the fuel injection pump to the cylinder block.

  1. NOTE:
    NOTE:Do not tighten the fuel injection pump support bracket to fuel injection pump bolts at this stage.
    Install the fuel injection pump and install the fuel injection pump support bracket to fuel injection pump bolts finger tight.

  1. NOTE:
    NOTE:Do not tighten the fuel injection pump sprocket retaining bolts at this stage.
    Install the fuel injection pump sprocket retaining bolts finger tight.

  1. Using the special tool, tighten the fuel pump retaining bolts.

  1. Remove the special tool.

  1. Install the fuel injection pump timing dowel to check the fuel injection pump timing.

  1. Tighten the fuel injection pump sprocket retaining bolts.

  1. Tighten the fuel injection pump support bracket to fuel injection pump bolts.

  1. Tighten the fuel injection pump support bracket to cylinder block bolts (fuel injection pump shown removed for clarity).

  1. Remove the fuel injection pump timing dowel.
  1. Using a suitable paint, mark the position of the crankshaft pulley in relation to the engine front cover.
  1. Raise the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Remove the special tool from the CKP sensor hole.
  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Turn the engine two revolutions.

  1. CAUTION:
    CAUTION:Do not turn the engine when the special tool is fully located into the flywheel. Failure to follow this instruction will cause damage to the CKP sensor hole.
    NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Turn the engine to 50 degrees before TDC and insert the special tool through the CKP sensor hole.
  1. Lower the vehicle.

  1. Insert the fuel injection pump timing dowel to check the fuel injection pump timing.

  1. CAUTION:
    CAUTION:Do not remove the fuel injection pump sprocket retaining bolts. Failure to follow this instruction may result in damage to the engine.
    Loosen the fuel injection pump sprocket retaining bolts.

  1. CAUTION:
    CAUTION:Do not make any adjustments to the timing chain tension using the fuel injection pump retaining bolts or nuts. Failure to follow this instruction may result in damage to the engine.
    Using a suitable screwdriver turn the fuel injection pump sprocket counterclockwise to tension the timing chain.

  1. Tighten the fuel injection pump sprocket retaining bolts.

  1. Remove the fuel injection pump timing dowel.

  1. Using the special tool, install the fuel injection pump sprocket access cover.
    • Install a new sprocket access cover.

  1. NOTE:
    NOTE:Make sure the fuel injection pump control unit electrical connector pins are clean.
    Connect the fuel injection pump control unit electrical connector.
    • Slide the locking tang into position.

  1. Connect the fuel supply and return lines to the fuel injection pump.
    For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).

  1. NOTE:
    NOTE:Install new high-pressure fuel supply lines.
    Install the high-pressure fuel supply lines.

  1. NOTE:
    NOTE:Do not tighten the high-pressure fuel supply line unions at this stage.
    Connect the high-pressure fuel supply lines to No. 1 and No. 2 fuel injectors.
  1. Raise the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Remove the special tool from the CKP sensor hole.
  1. Install the CKP sensor.
    For additional information, refer to: Crankshaft Position (CKP) Sensor - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel (303-14 Electronic Engine Controls, Removal and Installation).

  1. Connect the high-pressure fuel supply lines for No. 1 and No. 2 fuel injectors to the fuel injection pump.
  1. Lower the vehicle.

  1. NOTE:
    NOTE:Do not tighten the high-pressure fuel supply line unions at this stage.
    Connect the high-pressure fuel supply lines to No. 3 and No. 4 fuel injectors.
  1. Raise the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Connect the high-pressure fuel supply lines for No. 3 and No. 4 fuel injectors to the fuel injection pump.
  1. Lower the vehicle.
  1. Install the starter motor.
    For additional information, refer to: Starter Motor - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel (303-06 Starting System, Removal and Installation).
Left-hand drive vehicles
  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.
All Vehicles

  1. Disconnect the water-in-fuel sensor electrical connector (if equipped).

  1. Remove the fuel filter element.
    • Rotate the fuel filter element locking ring counterclockwise.

  1. Remove the water-in-fuel sensor (if equipped).
    • Discard the fuel filter.

  1. NOTE:
    NOTE:Install a new fuel filter.
    Install the water-in-fuel sensor (if equipped).

  1. NOTE:
    NOTE:Make sure the fuel filter element and the fuel filter housing are correctly aligned.
    Loosely install the fuel filter element.

  1. NOTE:
    NOTE:An audible click can be heard when the fuel filter element locking ring is correctly secured.
    Install the fuel filter element.
    • Rotate the fuel filter element locking ring clockwise.

  1. Connect the water-in-fuel sensor electrical connector (if equipped).

  1. Disconnect the fuel tank to fuel filter fuel supply line from the fuel filter.
    For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).

  1. Install the hand pressure pump special tool adapter to the fuel filter.

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

  1. NOTE:
    NOTE:Make sure the hand primer special tool 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 adapters.

  1. Operate the hand pressure pump special tool adapter until fuel starts to flow through the fuel filter.
  1. NOTE:
    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.

  1. NOTE:
    NOTE:Only one high-pressure fuel supply line will show signs of fuel escaping.
    Operate the fuel hand primer and tighten the high-pressure fuel supply line union which shows signs of fuel escaping.
  1. NOTE:
    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.
  1. Repeat Steps 51 and 52 to bleed the three remaining high-pressure fuel supply lines.

  1. Install the high-pressure fuel supply line support bracket.
    1. Install the outer retaining nuts.
    1. Install the center retaining nut.

  1. Attach the engine wiring harness to the high-pressure fuel supply line support bracket.
  1. Install the intake manifold.
    For additional information, refer to: Intake Manifold (303-01B Engine - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel, In-vehicle Repair).
All vehicles
  1. CAUTION:
    CAUTION:Do not operate the starter motor for longer than 10 seconds at a time. After 10 seconds, turn the ignition 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 to idle until it reaches normal operating temperature.
  1. Switch the engine off.
Left-hand drive vehicles
  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.
All vehicles

  1. Remove the hand pressure pump special tool from the hand pressure pump special tool adapters.

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

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

  1. Connect the fuel tank to fuel filter fuel fuel supply line to the fuel filter.
    For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).
Left-hand drive vehicles
  1. Remove the lint-free material from the generator.

Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04B Fuel Charging and Controls - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel Injection Pump

< PREV PAGE NEXT PAGE >