Fuel Charging and Controls — 3.

2L Duratorq-TDCi (148kW/200PS)
303-04C-1 - Puma 303-04C-1
.

SECTION 303-04C Fuel Charging and Controls — 3.2L

Duratorq-TDCi (148kW/200PS) - Puma

VEHICLE APPLICATION: 2011.50 Ranger

CONTENTS PAGE

DESCRIPTION AND OPERATION

Fuel Charging and Controls................................................................................................ 303-04C-2
Overview............................................................................................................................. 303-04C-2
General............................................................................................................................... 303-04C-2
Fuel pump........................................................................................................................... 303-04C-3
Fuel rail............................................................................................................................... 303-04C-3
Fuel injectors...................................................................................................................... 303-04C-4

GENERAL PROCEDURES
Fuel Injection Component Cleaning................................................................................... 303-04C-6

REMOVAL AND INSTALLATION

Fuel Pump.......................................................................................................................... 303-04C-8
Fuel Rail.............................................................................................................................. 303-04C-12
Fuel Injectors...................................................................................................................... 303-04C-14
 Fuel Charging and Controls — 3.2L Duratorq-TDCi (148kW/200PS)
303-04C-2 - Puma 303-04C-2
DESCRIPTION AND OPERATION

Fuel Charging and Controls

Overview

supplied to the fuel rail and fuel injector(s), in

Item Description
relation to the driving conditions.
1 Fuel rail The fuel is supplied at high-pressure to the fuel rail
2 Fuel injector(s) and to the fuel injectors ready for injection.
Depending on engine operating conditions, the fuel
3 Fuel pressure (FRP) sensor injection pressure varies between 230 bar and
4 Fuel metering valve 1600 bar.
5 Fuel temperature sensor Fuel system pressure is measured using an FRP
sensor located in the fuel rail. The FRP sensor
6 Fuel pump converts the fuel system pressure into a voltage
signal. This voltage signal acts as an input signal
to the powertrain control module (PCM) for
General calculation of the fuel injection quantity.
A common rail fuel injection system is used on the The power train control module (PCM) calculates
3.2L Duratorq-TDCi (Puma) diesel engine. the time of fuel injection and the fuel injection
quantity depending on various input variables. The
Within the fuel pump there is an integral fuel specified quantity of fuel is injected into the
transfer pump which draws the fuel from the fuel respective combustion chamber through the
tank to the fuel pump. solenoid actuated fuel injector(s). In doing so, a
A fuel metering valve is located in the supply port pre-injection and a main injection occur each time.
to the high-pressure chamber of the fuel pump. The excess fuel is returned to the fuel tank through
The fuel metering valve varies the quantity of fuel the fuel return line.

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 Fuel Charging and Controls — 3.2L Duratorq-TDCi (148kW/200PS)
303-04C-3 - Puma 303-04C-3
DESCRIPTION AND OPERATION
Fuel pump

Item Description
1 Fuel pump high-pressure outlet union
2 Fuel pump fuel return union
3 Fuel metering valve
4 Fuel temperature sensor
The fuel pump is driven directly by the timing belt.
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.

5 Fuel pump O-ring seal The fuel metering valve is actuated by the PCM
using pulse width modulation.
6 Fuel pump input drive
7 Fuel pump fuel supply union

Fuel rail

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 Fuel Charging and Controls — 3.2L Duratorq-TDCi (148kW/200PS)
303-04C-4 - Puma 303-04C-4
DESCRIPTION AND OPERATION
Item Description Fuel injectors
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 rail to fuel injector number 3
high-pressure fuel supply line union
4 Fuel pump to fuel rail high-pressure fuel
supply line union
5 Fuel rail to fuel injector number 4
high-pressure fuel supply line union
6 Fuel rail to fuel injector number 5
high-pressure fuel supply line union
7 Fuel rail
8 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 the Item Description
high-pressure fuel supply line(s) to the fuel
injector(s). 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.

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 Fuel Charging and Controls — 3.2L Duratorq-TDCi (148kW/200PS)
303-04C-5 - Puma 303-04C-5
DESCRIPTION AND OPERATION

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).

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 Fuel Charging and Controls — 3.2L Duratorq-TDCi (148kW/200PS)
303-04C-6 - Puma 303-04C-6
GENERAL PROCEDURES

Fuel Injection Component Cleaning

General Equipment components and connectors with lint-free
non-flocking material.
Pneumatic vacuum gun
1. For additional information, refer to: Solvents,
WARNINGS: Sealants and Adhesives (100-00 General
Information, Description and Operation)
Do not smoke or carry lighted tobacco or / Diesel Fuel System Health and Safety
open flame of any type when working on Precautions (100-00 General Information,
or near any fuel related components. Description and Operation).
Highly flammable mixtures are always
present and may ignite. Failure to follow 2.
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 CAUTION: Use lint free cloth.
suitable in view of the risk of
contamination to the fuel system. 3. Using Brake Cleaner: 3U7J-2C410-AA
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

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 Fuel Charging and Controls — 3.2L Duratorq-TDCi (148kW/200PS)
303-04C-7 - Puma 303-04C-7
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.

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 Fuel Charging and Controls — 3.2L Duratorq-TDCi (148kW/200PS)
303-04C-8 - Puma 303-04C-8
REMOVAL AND INSTALLATION

Fuel Pump
Special Tool(s) / General Equipment
303-1317
Locking Tool, Fuel Injection
Pump Sprocket

303-679
Remover/Installer, Engine
Front Cover Inspection Plate

Ford approved diagnostic tool

Ford Diagnostic Equipment

Removal

1. Refer to: Health and Safety Precautions (100-00

General Information, Description and
Operation).

WARNINGS:
Make sure that the engine is switched off.

Wait for a minimum of 1 minute after the

engine has stopped before commencing
any repair to the fuel injection system.
Make sure that the fuel pressure has
dropped to zero and that the fuel
temperature is at ambient temperature.
CAUTION: Extreme cleanliness must be
exercised when handling these
components.
2. General Equipment: Ford Diagnostic Equipment

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 Fuel Charging and Controls — 3.2L Duratorq-TDCi (148kW/200PS)
303-04C-9 - Puma 303-04C-9
REMOVAL AND INSTALLATION
3. Refer to: Battery Disconnect and Connect 9. Install the Special Tool(s): 303-1317
(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).
10. CAUTION: Make sure that all openings
5. Refer to: Intake Manifold (303-01 Engine - 3.2L are sealed. Use new blanking caps.
Duratorq-TDCi (148kW/200PS) - Puma, Vacuum foreign material from the low-pressure
Removal and Installation). fuel supply line and fuel return line.
6. Refer to: Fuel Injection Component Cleaning Refer to: Fuel Injection Component Cleaning
(303-04 Fuel Charging and Controls - 3.2L (303-04 Fuel Charging and Controls - 3.2L
Duratorq-TDCi (148kW/200PS) - Puma, Duratorq-TDCi (148kW/200PS) - Puma,
General Procedures). General Procedures).
7. Special Tool(s): 303-679

8. Torque: 64 Nm

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 Fuel Charging and Controls — 3.2L Duratorq-TDCi (148kW/200PS)
303-04C-10 - Puma 303-04C-10
REMOVAL AND INSTALLATION
11. 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

12. 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. 13. Torque: 23 Nm
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).

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 Fuel Charging and Controls — 3.2L Duratorq-TDCi (148kW/200PS)
303-04C-11 - Puma 303-04C-11
REMOVAL AND INSTALLATION
14. Torque: 23 Nm

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 approved diagnostic
tool

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 Fuel Charging and Controls — 3.2L Duratorq-TDCi (148kW/200PS)
303-04C-12 - Puma 303-04C-12
REMOVAL AND INSTALLATION

Fuel Rail
General Equipment
Ford Diagnostic Equipment

Removal
5.
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 6. CAUTIONS:
contain installation details. Make sure that the fuel line remains in
contact at both ends until both unions
2. Within the datalogger function, check that the nuts have been unscrewed and the area
fuel pressure has dropped to zero and that the around the joints thoroughly cleaned.
fuel temperature has either reached ambient Make sure that all openings are sealed.
temperature or is below 30ºC whichever is the Use new blanking caps.
greater.
Vacuum foreign material from the high-pressure
General Equipment: Ford Diagnostic Equipment fuel supply line, the fuel injector and the fuel rail.
3. Refer to: Battery Disconnect and Connect Refer to: Fuel Injection Component Cleaning
(414-01 Battery, Mounting and Cables, (303-04 Fuel Charging and Controls - 3.2L
General Procedures). Duratorq-TDCi (148kW/200PS) - Puma,
General Procedures).
4. Torque:
• Stage 1: 22 Nm
• Stage 2: 25 Nm

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 Fuel Charging and Controls — 3.2L Duratorq-TDCi (148kW/200PS)
303-04C-13 - Puma 303-04C-13
REMOVAL AND INSTALLATION
7. CAUTION: Make sure that all openings Torque:
are sealed. Use new blanking caps. • Fuel rail high-pressure fuel supply line
Vacuum foreign material from the fuel rail fuel unions
return line quick release coupling. • Stage 1: 5 Nm
• Stage 2: 35 Nm
Refer to: Fuel Injection Component Cleaning • Fuel rail high-pressure fuel supply line
(303-04 Fuel Charging and Controls - 3.2L bracket bolt 10 Nm
Duratorq-TDCi (148kW/200PS) - Puma,
General Procedures).

8. Refer to: Intake Manifold (303-01 Engine - 2.5L

Duratec-HE (122kW/165PS) - MI4, Removal
and Installation).
9. CAUTIONS: 10. Fuel rail bolts
Make sure that the fuel line remains in Torque:
contact at both ends until both unions • Stage 1: 6 Nm
nuts have been unscrewed and the area • Stage 2: 23 Nm
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).

Installation
1. To install, reverse the removal procedure.

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 Fuel Charging and Controls — 3.2L Duratorq-TDCi (148kW/200PS)
303-04C-14 - Puma 303-04C-14
REMOVAL AND INSTALLATION

Fuel Injectors
General Equipment
Ford Diagnostic Equipment
Long Nose Pliers

Removal

1. WARNINGS: 3. Refer to: Battery Disconnect and Connect

(414-01 Battery, Mounting and Cables,
Make sure that the engine is switched
General Procedures).
off.
Make sure that the fuel pressure has 4.
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 5.
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
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).

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 Fuel Charging and Controls — 3.2L Duratorq-TDCi (148kW/200PS)
303-04C-15 - Puma 303-04C-15
REMOVAL AND INSTALLATION

8.
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). 9. Torque:
Torque: • Stage 1: 5 Nm
• Stage 1: 22 Nm • Stage 2: 180°
• Stage 2: 25 Nm

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 Fuel Charging and Controls — 3.2L Duratorq-TDCi (148kW/200PS)
303-04C-16 - Puma 303-04C-16
REMOVAL AND INSTALLATION
10. General Equipment: Long Nose Pliers

Installation
1. To install, reverse the removal procedure.
2. Record the new fuel injector correction factor
code.

3. Input the new Injector Correction Factors using

the following WDS menu options:
ToolBox/Powertrain/Service Functions
General Equipment: Ford Diagnostic Equipment

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