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Fuel Pump > < Fuel Injection Component Cleaning

Transit 2006.5 (04.2006-)

Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel - Fuel Injectors Transit 2006.5 (04/2006-)
Removal and Installation

General Equipment
Long nose pliers
Worldwide Diagnostic System (WDS)

Removal

WARNING:
WARNING:Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General Information, Description and Operation).
WARNING:
WARNING:Make sure that the engine is switched off.
WARNING:
WARNING:Make sure that the fuel pressure has dropped to zero and that the fuel temperature is at ambient temperature.
WARNING:
WARNING:Wait for a minimum of 1 minute after the engine has stopped before commencing any repair to the fuel injection system.
CAUTION:
CAUTION:Fuel injectors must not be dismantled or the nozzles cleaned, not even with ultrasonic equipment. Install new fuel injectors if necessary.
CAUTION:
CAUTION:Fuel injectors sharing a common fuel injector clamp must be removed in pairs.
NOTE:
NOTE:Removal steps in this procedure may contain installation details.
  1. Within the datalogger function of WDS, check that the fuel pressure has dropped to zero and that the fuel temperature has either reached ambient temperature or is below 30ºC whichever is the greater.
    General Equipment: Worldwide Diagnostic System (WDS)
  1. Disconnect the battery ground cable.
    Refer to: Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Remove the air cleaner.
    Refer to: Air Cleaner - 2.2L Duratorq-TDCi (Puma) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).

  1. CAUTION:
    CAUTION:Make sure that all openings are sealed. Use new blanking caps.
    Vacuum foreign material from the fuel injector and fuel return lines.
    Refer to: Fuel Injection Component Cleaning (303-04C Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, General Procedures).

  1. CAUTION:
    CAUTION:Make sure that the fuel line remains in contact at both ends until both unions nuts have been unscrewed and the area around the joints thoroughly cleaned.
    CAUTION:
    CAUTION:Make sure that all openings are sealed. Use new blanking caps.
    Vacuum foreign material from the high-pressure fuel supply line, the fuel injector and the fuel rail.
    Refer to: Fuel Injection Component Cleaning (303-04C Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, General Procedures).
  1. Discard the high-pressure fuel supply lines.

  1. Discard the fuel injector clamp bolt.

  1. Discard the fuel injector copper seals from both removed fuel injectors making sure that the fuel injector nozzle is not damaged.
    General Equipment: Long nose pliers

Installation

  1. To install, reverse the removal procedure.

  1. Record the new fuel injector correction factor code.
  1. Install new fuel injector copper seals to both removed fuel injectors.

  1. Using a socket (or similar), press the new fuel injector copper seals onto the fuel injectors making sure that the copper seals are pushed fully home to prevent uneven clamping.
  1. Install a new fuel injector clamp bolt.
  1. Install new fuel injector high-pressure fuel supply lines.

  1. Tighten the bolts and unions in stages in the sequence indicated.
    Torque:
    Fuel injector clamp bolt 
    Stage 1:
    6 Nm
    Stage 2:
    180°
    Fuel injector high-pressure fuel supply line unions 
    Stage 1:
    5 Nm
    Stage 2:
    35 Nm
  1. Input the new Injector Correction Factors using the following WDS menu options: ToolBox/Powertrain/Service Functions
    General Equipment: Worldwide Diagnostic System (WDS)
  1. Carry out a Fuel System Leak Test using the following WDS menu options: ToolBox/Powertrain/Service Functions
    General Equipment: Worldwide Diagnostic System (WDS)
  1. Carry out the Pilot Correction Learn procedure using the following WDS menu options: ToolBox/Powertrain/Service Functions
    General Equipment: Worldwide Diagnostic System (WDS)

Fuel Pump > < Fuel Injection Component Cleaning