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Fuel Metering Valve > < Fuel Injection One-Way Valve

Transit 2000.5 (01.2000-05.2006)

Fuel Charging and Controls - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel - Fuel Injection Timing Solenoid Transit 2000.5 (01/2000-05/2006)
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 Intake manifold.
    For additional information, refer to: Intake Manifold - Vehicles Built Up To: 04/2003, Vehicles Without: Common Rail Fuel Injection (303-01A Engine - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
  1. 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. Remove the fuel injection pump support bracket plate.

  1. Remove the fuel injection pump support bracket.
  1. Using the pneumatic vacuum gun, clean the area around the fuel injection timing solenoid.

  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. 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 cylinder block. Secure the new fuel injection timing solenoid to the high-pressure fuel supply line using a cable-tie.
    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 support bracket.
    • Install the fuel injection pump support bracket retaining bolts hand tight.

  1. Install the fuel injection pump support bracket plate. Tighten the fuel injection pump support bracket plate retaining bolts in the sequence shown.
    1. Tighten the fuel injection pump support bracket plate to fuel injection pump retaining bolts to 10 Nm.
    1. Tighten the fuel injection pump support bracket plate to fuel injection pump engine support bracket retaining bolts to 22 Nm.

  1. Tighten the fuel injection pump engine support bracket retaining bolts.
  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).

  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 intake manifold.
    For additional information, refer to: Intake Manifold - Vehicles Built Up To: 04/2003, Vehicles Without: Common Rail Fuel Injection (303-01A Engine - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).

Fuel Metering Valve > < Fuel Injection One-Way Valve