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Transit 2000.5 (01.2000-05.2006)

Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel - Fuel Return Line Venturi Transit 2000.5 (01/2000-05/2006)
Removal and Installation

General Equipment
Pneumatic vacuum gun
Worldwide Diagnostic System (WDS)

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.
  1. Using datalogger in WDS, check that the fuel pressure has dropped to zero and that the fuel temperature has 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 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. Detach the camshaft position (CMP) sensor wiring harness from the intake manifold.

  1. Remove the intake manifold.
  1. Clean the fuel pump, fuel pump fuel return lines and surrounding area.
    For additional information, refer to: Fuel Injection Component Cleaning (303-04F Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel, General Procedures).

  1. Disconnect the fuel injector to fuel pump and fuel pump fuel return line quick release couplings.
    For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).
    • Install blanking plugs to the fuel pump and fuel line male and female connectors.
  1. Using the pneumatic vacuum gun, vacuum foreign material from the fuel pump, fuel return line venturi.

  1. Remove the fuel return line venturi.
    • Install a blanking plug to the open port on the fuel pump.

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. Always Install blanking plugs to any open orifices or lines.
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.
  1. Install the fuel return line venturi.
    • Discard the blanking plugs.
  1. Remove and discard the blanking plugs from the fuel return line venturi and fuel lines.

  1. Connect the fuel injector to fuel pump and fuel pump fuel return line quick release couplings.
    For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).

  1. Install the intake manifold.

  1. Attach the CMP sensor wiring harness to the intake manifold.
  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. Connect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

Fuel Rail > < Fuel Pump