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Fuel Pressure Relief Valve > < Fuel Pump

Transit 2006.5 (04.2006-)

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

General Equipment
Worldwide Diagnostic System (WDS)

Removal

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 at least 1 minute after the engine has stopped before commencing any repair to the fuel injection system.
CAUTION:
CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components.
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 and Connect (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 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 (303-04D Fuel Charging and Controls - 3.2L Duratorq-TDCi (Puma) Diesel, General Procedures).
  1. Discard the high-pressure fuel supply lines.

  1. Vacuum foreign material from the fuel rail fuel return line quick release coupling.
    Refer to: Fuel Injection Component Cleaning (303-04D Fuel Charging and Controls - 3.2L Duratorq-TDCi (Puma) Diesel, General Procedures).
  1. CAUTION:
    CAUTION:Make sure that all openings are sealed. Use new blanking caps.
    Disconnect the following items:
    • Fuel rail pressure (FRP) sensor electrical connector
    • Fuel rail fuel return line quick release coupling
      Refer to: Quick Release Coupling (310-00 Fuel System - General Information, 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 rail until both unions have been detached and 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 pump and the fuel rail.
    Refer to: Fuel Injection Component Cleaning (303-04D Fuel Charging and Controls - 3.2L Duratorq-TDCi (Puma) Diesel, General Procedures).
  1. Use an open-ended wrench to hold the fuel pump union while disconnecting the high-pressure fuel supply line from the fuel pump.
  1. Discard the high-pressure fuel supply line.

Installation

  1. To install, reverse the removal procedure.

  1. Install new fuel injector and fuel rail high-pressure fuel supply lines.
  1. Tighten the bolts and unions in two stages in the sequence indicated.
    Torque:
    Fuel rail bolts 
    Stage 1:
    6 Nm
    Stage 2:
    23 Nm
    Fuel rail high-pressure fuel supply line unions 
    Stage 1:
    5 Nm
    Stage 2:
    35 Nm
    Fuel injector high-pressure fuel supply line unions 
    Stage 1:
    5 Nm
    Stage 2:
    35 Nm
    Fuel rail high-pressure fuel supply line bracket bolt 10 Nm
  1. Carry out a Fuel System Leak Test using the following WDS menu options: ToolBox/Powertrain/Service Functions
    General Equipment: Worldwide Diagnostic System (WDS)

Fuel Pressure Relief Valve > < Fuel Pump