ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
Fuel Metering Valve > < Fuel Return Line Venturi

Transit 2000.5 (01.2000-05.2006)

Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel - Fuel Rail 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

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.
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 malfunction.
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. Open the bolt cover.

  1. Remove the accessory drive belt shield retaining bolts.

  1. Detach the fuel charging wiring harness and remove the accessory drive belt shield.
    • Cut the cable ties.

  1. Remove the engine oil filler pipe retaining clip and rotate the filler pipe to remove from the valve cover.
  1. Install the engine oil filler cap to the valve cover.
  1. Remove the Exhaust gas recirculation (EGR) valve.
    For additional information, refer to: Exhaust Gas Recirculation (EGR) Valve - 2.4L Duratorq-TDCi (Puma) Diesel (303-08 Engine Emission Control, Removal and Installation).

  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 open threaded ports of 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 pump fuel return line from the fuel pump.

  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. 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.

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: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. Using a suitable multi-purpose lubricant spray, lubricate the high-pressure fuel supply line union threads.
  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. Using a suitable multi-purpose lubricant spray, lubricate the high-pressure fuel supply line union threads.
  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 retaining bolts.

  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. 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. Connect the fuel pump fuel return line the the fuel pump.

  1. Install the intake manifold.

  1. Connect the fuel pressure sensor electrical connector.

  1. Connect the glow plug wire electrical connector.
  1. Install the EGR valve.
    For additional information, refer to: Exhaust Gas Recirculation (EGR) Valve - 2.4L Duratorq-TDCi (Puma) Diesel (303-08 Engine Emission Control, Removal and Installation).
  1. Remove the engine oil filler cap from the valve cover.
  1. Install the engine oil filler pipe to the valve cover.

  1. Attach the fuel charging wiring harness and install the accessory drive belt shield.

  1. Install the accessory drive belt shield retaining bolts.
  1. Open the bolt cover.
  1. Connect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

Fuel Metering Valve > < Fuel Return Line Venturi