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ford Workshop Repair Guides


Transit 2006.5 (04.2006-)

Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04C Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Fuel Pump

Removal

WARNING:
WARNING:Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
WARNING:
WARNING:Make sure that the engine is switched off.
WARNING:
WARNING:Wait for a minimum of 1 minute after the engine has stopped before commencing any repair to the fuel injection system.
WARNING:
WARNING:Make sure that the fuel pressure has dropped to zero and that the fuel temperature is at ambient temperature.
CAUTION:
CAUTION:Extreme cleanliness must be exercised when handling these components.
Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel - Fuel Pump Transit 2006.5 (04/2006-)
Removal and Installation

Special Tool(s)

303-1151
Locking Tool, Fuel Injection Pump Sprocket

303-249
Remover, Crankshaft Timing Pulley

303-679
Remover/Installer, Engine Front Cover Inspection Plate
General Equipment
Ford approved diagnostic tool
  1. General Equipment: Ford approved diagnostic tool
  1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Refer to: Accessory Drive Belt - 2.4L Duratorq-TDCi (Puma) Diesel/3.2L Duratorq-TDCi (Puma) Diesel (303-05 Accessory Drive, Removal and Installation).
  1. Refer to: Intake Manifold (303-01 Engine - 2.4L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
  1. Refer to: Fuel Injection Component Cleaning (303-04C, General Procedures).

  1. Special Tool(s): 303-679

  1. Install the Special Tool(s): 303-1151

  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.

  1. CAUTION:
    CAUTION:Make sure that all openings are sealed. Use new blanking caps.
    1. Refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Install the Special Tool(s): 303-249

Installation

  1. Remove the Special Tool(s): 303-249

  1. Torque: 23 Nm

  1. Torque:
    1: 64 Nm
    2: 33 Nm

  1. Remove the Special Tool(s): 303-1151

  1. Special Tool(s): 303-679

  1. Refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Install the following items:
    1. Torque: 10 Nm
    1. NOTE:
      NOTE:Make sure that a new component is installed.
      Torque:
      Stage 1:
      5 Nm
      Stage 2:
      35 Nm
  1. Refer to: Intake Manifold (303-01 Engine - 2.4L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
  1. Refer to: Accessory Drive Belt - 2.4L Duratorq-TDCi (Puma) Diesel/3.2L Duratorq-TDCi (Puma) Diesel (303-05 Accessory Drive, Removal and Installation).
  1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Refer to: Fuel Filter Element - Diesel (310-01 Fuel Tank and Lines, Removal and Installation).
  1. Refer to: Fuel System Bleeding (310-00 Fuel System - General Information, General Procedures).
  1. Carry out a Fuel System Leak Test using the following menu options: ToolBox/Powertrain/Service Functions
    General Equipment: Ford approved diagnostic tool
  1. Carry out a Pump Learn procedure using the following menu options: ToolBox/Powertrain/Service Functions
    General Equipment: Ford approved diagnostic tool
  1. Carry out the Pilot Correction Learn procedure using the following menu options: ToolBox/Powertrain/Service Functions
    General Equipment: Ford approved diagnostic tool

Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04C Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Fuel Pump

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