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Fuel Return Line Venturi > < Fuel Pump

Transit 2000.5 (01.2000-05.2006)

Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel - Fuel Injection Supply Manifold Transit 2000.5 (01/2000-05/2006)
Removal and Installation

Special Tool(s)

Aligner, Fuel Injector

303-711 (21-258)
General Equipment
Worldwide Diagnostic System (WDS)
Pneumatic vacuum gun
Materials
Name
Specification
High-pressure fuel supply line union lubricant
TBD
TBD

Removal

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.
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 either reached ambient temperature or is below 30º C. whichever is the 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:Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfuction.
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.
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.
  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 30º C. whichever is the greater.
  1. Disconnect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

  1. Remove the engine oil filler pipe.

  1. Remove the intake air resonator retaining nuts.

  1. Remove the air cleaner outlet pipe and intake air resonator.
Vehicles built up to 10/2002
  1. Remove the engine upper cover.
All vehicles
  1. Install the engine oil filler cap to the valve cover.

  1. Disconnect the exhaust gas recirculation (EGR) valve to intake manifold inlet pipe from the intake manifold.

  1. Disconnect the glow plug wire electrical connector.

  1. Disconnect the fuel pressure sensor electrical connector.

  1. Remove the intake manifold.
  1. 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 (303-04F Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel, General Procedures).

  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel injector and the fuel injection supply manifold until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    CAUTION:
    CAUTION:Make sure the tool used to loosen the high-pressure fuel supply line unions is used at the top of the unions as this is where there is most material. Failure to follow this instruction may result in damage to the unions.
    CAUTION:
    CAUTION:Make sure that the fuel injector does not move when loosening the high-pressure fuel supply lines. Failure to follow this instruction will result in damage to the fuel injector and the fuel injector sealing washer.
    Loosen the high-pressure fuel supply lines from the fuel injectors and the fuel injection supply manifold.
  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel injector and the fuel injection supply manifold until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    Using the pneumatic vacuum gun, vacuum foreign material from the fuel injector and the fuel injection supply manifold.
  1. Remove and discard the high-pressure fuel supply lines.
  1. Using the pneumatic vacuum gun, vacuum foreign material from the fuel injector and the fuel injection supply manifold.
  1. Install blanking caps to the open threaded ports on the fuel injectors and the fuel injection supply manifold.

  1. Disconnect the fuel metering valve and fuel temperature sensor electrical connectors and protect them with lint-free material to prevent contamination from the cleaning fluid.

  1. Remove the high-pressure fuel supply line clamp.
  1. Clean the fuel pump, high-pressure fuel supply line and surrounding areas.
    For additional information, refer to: Fuel Injection Component Cleaning (303-04F Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel, General Procedures).

  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel pump and the fuel injection supply manifold until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    CAUTION:
    CAUTION:Make sure the tool used to loosen the high-pressure fuel supply line union is used at the top of the union as this is where there is most material. Failure to follow this instruction may result in damage to the union.
    CAUTION:
    CAUTION:Maintain pressure on the high-pressure fuel supply line to keep the olive in contact with the fuel pump cone while unscrewing the union. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    Loosen the high-pressure fuel line at the fuel pump.
  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel pump and the fuel injection supply manifold until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply line and the fuel pump.

  1. CAUTION:
    CAUTION:Make sure the tool used to loosen the high-pressure fuel supply line union is used at the top of the union as this is where there is most material. Failure to follow this instruction may result in damage to the union.
    CAUTION:
    CAUTION:Maintain pressure on the high-pressure fuel supply line to keep the olive in contact with the fuel injection supply manifold cone while unscrewing the union. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    CAUTION:
    CAUTION:While maintaining the pressure on the high-pressure fuel supply line, clean and vacuum foreign material from the line and union.
    Remove and discard the high-pressure fuel supply line.
  1. Using the pneumatic vacuum gun, vacuum foreign material from the fuel pump and the fuel injection supply manifold.
  1. Install blanking caps to the open threaded ports on the fuel pump and the fuel injection supply manifold.

  1. Remove the fuel injection supply manifold retaining studs.

  1. Remove the fuel injection supply manifold support brackets.

  1. Remove the fuel injection supply manifold.

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.
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:Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfuction.
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.
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 the fuel injectors or clean the nozzles, even with an ultrasonic cleaner. Always install new fuel injectors when required.
NOTE:
NOTE:Install new high-pressure fuel supply lines.
  1. NOTE:
    NOTE:Do not tighten the fuel injection supply manifold retaining bolt at this stage.
    Install the fuel injection supply manifold.

  1. NOTE:
    NOTE:Do not tighten the fuel injection supply manifold support bracket bolts at this stage.
    Install the fuel injection supply manifold support brackets.

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

  1. Lubricate the high-pressure fuel supply line union threads with clean lubricant.
  1. CAUTION:
    CAUTION:Do not allow the unions to hit the olive ends of the high-pressure fuel supply line as this may damage the ends of the line and allow foreign matter to enter the fuel injection system.
    NOTE:
    NOTE:The yellow colored collar is fitted at the fuel pump end and the blue colored collar is fitted at the fuel injection supply manifold end of the high-pressure fuel supply line.
    NOTE:
    NOTE:To aid identification of the high-pressure fuel supply lines, the union at the fuel pump end is etched with the word Pump.
    Position the high-pressure fuel supply line as near to the final installation position as possible and then remove and discard the blanking plugs from the high-pressure fuel supply line.
  1. Remove the blanking plugs from the fuel pump and the fuel injection supply manifold threaded ports.
    • Discard the blanking plugs.

  1. CAUTION:
    CAUTION:Do not tighten the high-pressure fuel supply line union at this stage.
    CAUTION:
    CAUTION:Maintain pressure on the high-pressure fuel supply line to keep the olive in contact with the fuel pump cone while hand installing the union. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    Install a new high-pressure fuel supply line to the fuel pump.

  1. CAUTION:
    CAUTION:Do not tighten the high-pressure fuel supply line union at this stage.
    CAUTION:
    CAUTION:Maintain pressure on the high-pressure fuel supply line to keep the olive in contact with the fuel injection supply manifold cone while hand installing the union. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    Install the high-pressure fuel supply line to the fuel injection supply manifold.

  1. Lubricate the high-pressure fuel supply line union threads with clean lubricant.
  1. CAUTION:
    CAUTION:Do not allow the unions to hit the olive ends of the high-pressure fuel supply line as this may damage the ends of the line and allow foreign matter to enter the fuel injection system.
    NOTE:
    NOTE:The yellow colored collar is fitted at the fuel injector end and the blue colored collar is fitted at the fuel supply manifold end of the high-pressure fuel supply line.
    NOTE:
    NOTE:To aid identification of the high-pressure fuel supply line, the union at the fuel injector end is etched with the cylinder number.
    Position the high-pressure fuel supply line as near to the final installation position as possible and then remove and discard the blanking plugs from the high-pressure fuel supply line.
  1. Remove the blanking plugs from the fuel injector and the fuel injection supply manifold threaded ports.
    • Discard the blanking plugs.

  1. CAUTION:
    CAUTION:Maintain pressure on the high-pressure fuel supply line to keep the olives in contact with the fuel injectors and the fuel injection supply manifold cones while hand installing the unions.
    NOTE:
    NOTE:Install the high-pressure fuel supply lines to the fuel injection supply manifold end first followed by the fuel injector end.
    NOTE:
    NOTE:Do not tighten the high-pressure fuel supply line unions at this stage.
    Install new high-pressure fuel supply lines.

  1. Tighten the fuel injection supply manifold support brackets.

  1. Tighten the fuel injection supply manifold retaining studs.

  1. CAUTION:
    CAUTION:Make sure the special tool is clamped around the fuel injector which is being tightened and is resting up against the adjacent fuel injector.
    CAUTION:
    CAUTION:Make sure the tool used to tighten the high-pressure fuel supply line unions is used at the top of the union as this is where there is most material. Failure to follow this instruction may result in damage to the union.
    CAUTION:
    CAUTION:Make sure that the fuel injector does not move when tightening the high-pressure fuel supply lines. Failure to follow this instruction will result in damage to the fuel injector and the fuel injector sealing washer.
    Install the special tool and tighten the high-pressure fuel supply line union(s) at the fuel injector(s)
  1. Repeat step 17 for tightening the three remaining high-pressure fuel supply line unions at the fuel injectors.
  1. Remove the special tool.

  1. CAUTION:
    CAUTION:Make sure the tool used to tighten the high-pressure fuel supply line unions is used at the top of the union as this is where there is most material. Failure to follow this instruction may result in damage to the union.
    Tighten the high-pressure fuel supply line unions at the fuel injection supply manifold.

  1. Install the high-pressure fuel supply line clamp.

  1. CAUTION:
    CAUTION:Make sure the tool used to tighten the high-pressure fuel supply line union is used at the top of the union as this is where there is most material. Failure to follow this instruction may result in damage to the union.
    CAUTION:
    CAUTION:Make sure the tool used to tighten the high-pressure fuel supply line union does not come into contact with the inlet metering valve while tightening the high-pressure fuel supply line union. Failure to follow this instruction may result in fuel leaking from the union.
    Tighten the high-pressure fuel supply line union at the fuel pump.

  1. CAUTION:
    CAUTION:Make sure the tool used to tighten the high-pressure fuel supply line union is used at the top of the union as this is where there is most material. Failure to follow this instruction may result in damage to the union.
    Tighten the high-pressure fuel supply line union at the fuel injection supply manifold.
  1. NOTE:
    NOTE:Remove the lint-free material from the electrical connectors.
    Connect the fuel metering valve and fuel temperature sensor electrical connectors.

  1. Install the intake manifold.

  1. Connect the fuel pressure sensor electrical connector.

  1. Connect the glow plug wire electrical connector.

  1. Connect the EGR valve to intake manifold inlet pipe to the intake manifold.

  1. Remove the engine oil filler cap from the valve cover.
Vehicles built up to 10/2002
  1. Install the engine upper cover.
All vehicles
  1. Install the air cleaner outlet pipe and intake air resonator.

  1. Install the intake air resonator retaining nuts.

  1. Install the engine oil filler pipe.
  1. Connect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

Fuel Return Line Venturi > < Fuel Pump