303-04B Alimentação de combustível 2.2

Fuel Charging and Controls – 2.2L Duratorq-TDCi (88kW/120PS) 303-04B-1 303-04B-1 - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma . SECTION 303-04B Fuel Charging and Controls – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma VEHICLE APPLICATION: 2011.50 Ranger CONTENTS DESCRIPTION AND OPERATION Fuel Charging and Controls................................................................................................ Overview............................................................................................................................. General............................................................................................................................... Fuel pump........................................................................................................................... Fuel rail............................................................................................................................... Fuel injectors...................................................................................................................... GENERAL PROCEDURES Fuel Injection Component Cleaning................................................................................... REMOVAL AND INSTALLATION Fuel Injectors...................................................................................................................... Fuel Pump.......................................................................................................................... Fuel Rail.............................................................................................................................. PAGE 303-04B-2 303-04B-2 303-04B-2 303-04B-3 303-04B-3 303-04B-4 303-04B-6 303-04B-8 303-04B-11 303-04B-15

Fuel Charging and Controls – 2.2L Duratorq-TDCi (88kW/120PS) 303-04B-2 303-04B-2 - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma DESCRIPTION AND OPERATION Fuel Charging and Controls Overview 1 6 E129441 Item Description 1 Fuel rail 2 Fuel rail pressure (FRP) sensor 3 Fuel Injector(s) 4 Fuel metering valve 5 Fuel temperature sensor 6 Fuel pump General A Denso common rail fuel injection system is used on the 2.2L Duratorq-TDCi (Puma) diesel engine. Within the fuel pump there is an integral fuel transfer pump which draws the fuel from the fuel tank to the fuel pump. A fuel metering valve is located in the supply port to the high-pressure chamber of the fuel pump. The fuel metering valve varies the quantity of fuel 2 4 3 5 supplied to the fuel rail and fuel injector(s), in relation to the driving conditions. The fuel is supplied at high-pressure to the fuel rail and to the fuel injectors ready for injection. Depending on engine operating conditions, the fuel injection pressure varies between 230 bar and 1600 bar. Fuel system pressure is measured using an FRP sensor located in the fuel rail. The FRP sensor converts the fuel system pressure into a voltage signal. This voltage signal acts as an input signal to the powertrain control module (PCM) for calculation of the fuel injection quantity. The power train control module (PCM) calculates the time of fuel injection and the fuel injection quantity depending on various input variables. The specified quantity of fuel is injected into the respective combustion chamber through the solenoid actuated fuel injector(s). In doing so, a pre-injection and a main injection occur each time. The excess fuel is returned to the fuel tank through the fuel return line.

Fuel Charging and Controls – 2.2L Duratorq-TDCi (88kW/120PS) 303-04B-3 303-04B-3 - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma DESCRIPTION AND OPERATION Fuel pump 3 1 2 7 E129442 Item Description 1 Fuel pump high-pressure outlet union 2 Fuel pump fuel return union 3 Fuel metering valve 4 Fuel temperature sensor 5 Fuel pump O-ring seal 6 Fuel pump input drive 7 Fuel pump fuel supply union Fuel rail 1 2 3 E129443 5 4 6 The fuel pump is driven directly by the intake camshaft and is located at the rear of the cylinder head. The fuel pump has three pump elements, each offset from each other by 120 degrees. The fuel transfer pump is incorporated into the fuel pump and is located on the drive flange. The fuel transfer pump is a cycloid type pump. The fuel metering valve is actuated by the PCM using pulse width modulation. 4 5 6 7

Fuel Charging and Controls – 2.2L Duratorq-TDCi (88kW/120PS) 303-04B-4 303-04B-4 - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma DESCRIPTION AND OPERATION Item Description 1 Fuel rail to fuel injector number 1 high-pressure fuel supply line union 2 Fuel rail to fuel injector number 2 high-pressure fuel supply line union 3 Fuel pump to fuel rail high-pressure fuel supply line union 4 Fuel rail to fuel injector number 3 high-pressure fuel supply line union 5 Fuel rail to fuel injector number 4 high-pressure fuel supply line union 6 Fuel rail 7 FRP sensor CAUTION: The FRP sensor must not be detached or removed from the fuel rail. The fuel rail is made from forged steel and is retained by a support bracket located on the camshaft carrier . The fuel is delivered by one high-pressure fuel supply line from the fuel pump to the fuel rail. From the fuel rail, the fuel travels through high-pressure fuel supply line(s) to the fuel injector(s). Fuel injectors 1 6 2 3 5 4 E129444 Item Description 1 Fuel injector electrical connector 2 Fuel injector fuel return line clip 3 Fuel injector 4 Fuel injector sealing washer 5 Fuel injector nozzle 6 Fuel injector high-pressure fuel supply line union The fuel injector(s) are located centrally on the cylinder head upper section and are attached by means of retaining clamps. The fuel injector(s) are sealed from the combustion chamber by means of a copper sealing washer located between the fuel injector and the cylinder head. A new sealing washer must always be installed when carrying out installation work. The fuel injectors are controlled directly by the PCM. The fuel return line(s) are attached to the top of the fuel injector and are connected in series.

Fuel Charging and Controls – 2.2L Duratorq-TDCi (88kW/120PS) 303-04B-5 303-04B-5 - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma DESCRIPTION AND OPERATION F100-0000 1 0000-00F1 2 E129445 Item Description 1 Eight digit injector correction factor (example only shown) 2 Eight digit serial code (For manufacturer use only) When installing new fuel injectors, the injector correction factor from the new fuel injector(s) must be recorded and uploaded using the Worldwide Diagnostic System (WDS).

Fuel Charging and Controls – 2.2L Duratorq-TDCi (88kW/120PS) 303-04B-6 303-04B-6 - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma GENERAL PROCEDURES Fuel Injection Component Cleaning General Equipment Pneumatic vacuum gun WARNINGS: 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. 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. Eye protection must be worn at all times when working on or near any fuel related components. Failure to follow this instruction may result in personal injury. CAUTIONS: Make sure that the workshop area in which the vehicle is being worked on is as clean and dust-free as possible. Areas in which work on clutches, brakes or where welding or machining are carried out are not suitable in view of the risk of contamination to the fuel system. Make sure that clean non-plated tools are used. Clean tools using a new brush that will not lose its bristles and fresh suitable evaporative cleaning agent, prior to starting work on the vehicle. Use a steel topped workbench and cover it with clean, lint-free non-flocking material. Make sure that all parts removed from the vehicle are placed on the lint-free non-flocking material. Make sure that any protective clothing worn is clean and made from lint-free non-flocking material. Make sure that any protective gloves worn are new and are of the non-powdered latex type. Before using the suitable evaporative cleaning agent, protect all electrical components and connectors with lint-free non-flocking material. 1. For additional information, refer to: Solvents, Sealants and Adhesives (100-00 General Information, Description and Operation) / Diesel Fuel System Health and Safety Precautions (100-00 General Information, Description and Operation). 2. E121677 CAUTION: Use lint free cloth. 3. Using Brake Cleaner: 3U7J-2C410-AA E121676

Fuel Charging and Controls – 2.2L Duratorq-TDCi (88kW/120PS) 303-04B-7 303-04B-7 - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma GENERAL PROCEDURES 4. Using a new brush that will not lose its bristles, brush a suitable evaporative cleaning agent onto the components being removed and onto the surrounding area. 5. Using the pneumatic vacuum gun, remove all traces of evaporative cleaning agent and foreign material. 6. Dispose of any unused evaporative cleaning agent and the brush after completing the repair.

Fuel Charging and Controls – 2.2L Duratorq-TDCi (88kW/120PS) 303-04B-8 303-04B-8 - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Fuel Injectors General Equipment Ford Diagnostic Equipment Removal 1. WARNINGS: Make sure that the engine is switched off. Make sure that the fuel pressure has dropped to zero and that the fuel temperature is at ambient temperature. Wait for a minimum of 1 minute after the engine has stopped before commencing any repair to the fuel injection system. CAUTIONS: Fuel injectors must not be dismantled or the nozzles cleaned, not even with ultrasonic equipment. Install new fuel injectors if necessary. Fuel injectors sharing a common fuel injector clamp must be removed in pairs. NOTE: Removal steps in this procedure may contain installation details. Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General Information, Description and Operation). 2. 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: Ford Diagnostic Equipment General Equipment Long Nose Pliers 3. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 4. E129579 5. E129766 6. 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 (303-04 Fuel Charging and Controls - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures).

Fuel Charging and Controls – 2.2L Duratorq-TDCi (88kW/120PS) 303-04B- 303-04B- - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION x4 E129580 7. CAUTIONS: 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. 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 (303-04 Fuel Charging and Controls - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures). Torque: ‡ Stage 1: 22 Nm ‡ Stage 2: 25 Nm x4 x4 E129581 2 1 8. x4 x3 E129582 9. Torque: ‡ Stage 1: 5 Nm ‡ Stage 2: 180° x2 E129583

Fuel Charging and Controls – 2.2L Duratorq-TDCi (88kW/120PS) 303-04B-10 303-04B-10 - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 10.General Equipment: Long Nose Pliers E129584 Installation 1. To install, reverse the removal procedure. 2. Record the new fuel injector correction factor code. F100-0000 E129647 3. Input the new Injector Correction Factors using the following WDS menu options: ToolBox/Powertrain/Service Functions General Equipment: Ford Diagnostic Equipment

Fuel Charging and Controls – 2.2L Duratorq-TDCi (88kW/120PS) 303-04B-11 303-04B-11 - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Fuel Pump Special Tool(s) / General Equipment 303-1317 Locking Tool, Fuel Injection Pump Sprocket E75376 303-249 Remover, Crankshaft Timing Pulley 21132 Removal 1. WARNINGS: Make sure that the engine is switched off. Make sure that the fuel pressure has dropped to zero and that the fuel temperature is at ambient temperature. Wait for a minimum of 1 minute after the engine has stopped before commencing any repair to the fuel injection system. NOTE: Vacuum any foreign material from the fuel pump and fuel rail unions before sealing the unions with blanking caps. NOTE: Removal steps in this procedure may contain installation details. Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General Information, Description and Operation). 2. Within the datalogger function, 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: Ford Diagnostic Equipment Special Tool(s) / General Equipment 303-679 Remover/Installer, Engine Front Cover Inspection Plate Ford Diagnostic Equipment

Fuel Charging and Controls – 2.2L Duratorq-TDCi (88kW/120PS) 303-04B-12 303-04B-12 - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 3. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 4. Refer to: Accessory Drive Belt - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma (303-05 Accessory Drive - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 5. Refer to: Intake Manifold (303-01 Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Removal and Installation). 6. Refer to: Fuel Injection Component Cleaning (303-04 Fuel Charging and Controls - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures). 7. Special Tool(s): 303-679 303-679 E129923 8. Torque: 64 Nm E139269 9. Install the Special Tool(s): 303-1317 303-1317 E97221 10.Special Tool(s): 303-249 303-1317 303-249 E97222 11. CAUTION: Make sure that all openings are sealed. Use new blanking caps. Vacuum foreign material from the low-pressure fuel supply line and fuel return line. Refer to: Fuel Injection Component Cleaning (303-04 Fuel Charging and Controls - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures). E129686

Fuel Charging and Controls – 2.2L Duratorq-TDCi (88kW/120PS) 303-04B-13 303-04B-13 - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 12. E129687 13.CAUTIONS: 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. 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 (303-04 Fuel Charging and Controls - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures). Torque: ‡ Fuel rail 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 E129688 14.Torque: 23 Nm E129689

Fuel Charging and Controls – 2.2L Duratorq-TDCi (88kW/120PS) 303-04B-14 303-04B-14 - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 15.Torque: 23 Nm x3 E129690 Installation 1. To install, reverse the removal procedure. 2. Carry out a Fuel System Leak Test using the following menu options: ToolBox/Powertrain/Service Functions General Equipment: Ford Diagnostic Equipment 3. Carry out a Pump Learn procedure using the following menu options: ToolBox/Powertrain/Service Functions General Equipment: Ford Diagnostic Equipment 4. Carry out the Pilot Correction Learn procedure using the following menu options: ToolBox/Powertrain/Service Functions General Equipment: Ford Diagnostic Equipment

Fuel Charging and Controls – 2.2L Duratorq-TDCi (88kW/120PS) 303-04B-15 303-04B-15 - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Fuel Rail General Equipment Ford Diagnostic Equipment Removal 1. WARNINGS: Make sure that the engine is switched off. Make sure that the fuel pressure has dropped to zero and that the fuel temperature is at ambient temperature. Wait at least 1 minute after the engine has stopped before commencing any repair to the fuel injection system. CAUTION: Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. NOTE: Removal steps in this procedure may contain installation details. 2. 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: Ford Diagnostic Equipment 3. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 4. Refer to: Air Cleaner - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma (303-12 Intake Air Distribution and Filtering - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 5. E129579 6. E129766 7. CAUTIONS: Make sure that the fuel line remains in contact at both ends until both unions

Fuel Charging and Controls – 2.2L Duratorq-TDCi (88kW/120PS) 303-04B-16 303-04B-16 - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION nuts have been unscrewed and the area around the joints thoroughly cleaned. 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 (303-04 Fuel Charging and Controls - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures). Torque: ‡ Stage 1: 22 Nm ‡ Stage 2: 25 Nm x4 x4 E129581 8. CAUTION: Make sure that all openings are sealed. Use new blanking caps. Vacuum foreign material from the fuel rail fuel return line quick release coupling. Refer to: Fuel Injection Component Cleaning (303-04 Fuel Charging and Controls - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures). E129704 9. Refer to: Intake Manifold (303-01 Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Removal and Installation). 10.CAUTIONS: 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. 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 (303-04 Fuel Charging and Controls - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures). Torque: ‡ Fuel rail 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 E129688

Fuel Charging and Controls – 2.2L Duratorq-TDCi (88kW/120PS) 303-04B-17 303-04B-17 - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 11. Fuel rail bolts Torque: ‡ Stage 1: 6 Nm ‡ Stage 2: 23 Nm x2 E129705 Installation 1. To install, reverse the removal procedure. 2. Carry out a Fuel System Leak Test using the following WDS menu options: ToolBox/Powertrain/Service Functions General Equipment: Ford Diagnostic Equipment