Swapping fuel pump 2.0l Duratorq 75ps to 85ps

[White2Blue]

Hi all,

My old transit 2002 75ps 130k miles, has suffered transmission failure, I changed the Metering solenoid on the fuel pump about a year ago.

I bought my new transit 2004 85ps 46k miles from a gent who had the pump ecu changed and couldn't bear to invest more in the van when it still wouldn't start. It used to fail to start every now and again and it just got worse until wouldn't start at all. Codes P1664 and P1554. When the ecu change didn't work he was told that a new/recon pump would sort it.

The van is in such good condition I thought it would be worth the risk.

I'm removing the old fuel pump (planning to take it to Bosch DTM for virginalising).

Problem 1: I Can't locate the CPS on the transmission! A little pointer would help...do I have to access it from under the van?

Problem 2: When the timing pin (6mm bit) is in the fuel pump timing slot (12pm on the sprocket) the 3 T45 bolt holes are covered by the timing cover lugs...They line up about a quarter turn later (clockwise of course)...the only way I can see this happening is if the sprocket has been previously taken off and put back on 1 bolt out of alignment? Possibly during a timing chain change?

I'm not too fussed with damaging the old van, but I'll need to get it right when I do the new one!

Many Thanks!

[White2Blue]

Having thought and done more research, I’m pretty sure the CkP sensor is difficult to access (esp on the 2002 Transit as it seems to be under the egr valve and beyond wheras the 2004 Transit’s egr valve is on the timing cover side.

The 2002 Transit was a pretty noisy engine, a bit tractor like... I wonder if it could have anything to do with the timing chain not being properly tensioned. Also I’ve read that there can be some play in the sprocket for slight adjustment...

[ned]

The cps is on top/side of gearbox above the flywheel easy to get to from under the van, well mine is anyway. N

[martynx]

The cps is on top/side of gearbox above the flywheel easy to get to from under the van, well mine is anyway. N

Is the CKS on the head high up near cylinder #4?

[White2Blue]

I have it up on axle stands only on the first setting, I think I may need to get it higher...

I did find a cable going to (presumably) a sensor on a part of the transmission which is in line with the driveshaft, but that's too far back I assume as it's not on top of the flywheel! Probably a speed sensor?

[martynx]

I have it up on axle stands only on the first setting, I think I may need to get it higher...

I did find a cable going to (presumably) a sensor on a part of the transmission which is in line with the driveshaft, but that's too far back I assume as it's not on top of the flywheel! Probably a speed sensor?

Speed sensor yes. Then right on the selector mechanism theres the reverse lamp switch.

[White2Blue]

Ah yep that makes sense!

[bambi mk 1]

[quote="ned"]The cps is on top/side of gearbox above the flywheel easy to get to from under the van, well mine is anyway. N[/quote ]Dats cause you are always under it Ned

[ned]

The cps is on top/side of gearbox above the flywheel easy to get to from under the van, well mine is anyway. N

Is the CKS on the head high up near cylinder #4?

What's the cks (cam knock sensor)? I thought the op was looking for the crank position sensor N

[ned]

The cps is on top/side of gearbox above the flywheel easy to get to from under the van, well mine is anyway. N[/quote ]Dats cause you are always under it Ned

Yes unless I'm pissing about with the bloody fuel system I now have a big yellow sticker on the engine that reads 'ned step away, put the bonnet down and piss off' N

[White2Blue]

The cps is on top/side of gearbox above the flywheel easy to get to from under the van, well mine is anyway. N

Is the CKS on the head high up near cylinder #4?

What's the cks (cam knock sensor)? I thought the op was looking for the crank position sensor N

Hi, sorry that’s my fault. I’ve always known the Crank position sensor to be abbreviated as CPS. The more I read, it’s supposed to be abbreviated CKP sensor, I suppose to differenciate between the Cam position sensor!

I want the crank for sure!

[martynx]

[quote="ned"]The cps is on top/side of gearbox above the flywheel easy to get to from under the van, well mine is anyway. N

Is the CKS on the head high up near cylinder #4?

What's the cks (cam knock sensor)? I thought the op was looking for the crank position sensor N

Hi, sorry that’s my fault. I’ve always known the Crank position sensor to be abbreviated as CPS. The more I read, it’s supposed to be abbreviated CKP sensor, I suppose to differenciate between the Cam position sensor!

I want the crank for sure![/quote] ,

Whatever we all name it , i was pointing out the camshaft postion sensors
location - , not what you need sorry .


Too many k's & m's lol..

[APH]

The pump timing pin goes in at about 2 o'clock position, not 12, which is why the holes didn't line up.

The ckp sensor is on the bell housing near the top, much easier to get at from below than above.

Andy

[White2Blue]

Ah Brilliant!

Thanks Andy, thought I had read something about it being the 2 o’clock position...

I am still a bit confused though... when I put the 6mm bit in at 12 o’clock it fits lovely and snug. I gently tried turning the crank it would jam the 6mm bit... and it also says about the 12 o’clock position in the ford workshop manual and the haynes.

Having said all that I hadn’t done the crank pin, so maybe the 12 o’clock position is recommended before trying to do the crank pin as it’s close to the 2o’clock position which makes it more straight forward to find the crank pin gap in the flywheel...

[White2Blue]

Roght, got another hour or so on it today...

Got right under the van and from behind the steering rack I could reach the sensor on top if the bell housing. All out and 14mm pin placed in there... I was hoping if I turn the crank at least a couple of full turns that it would drop the pin...not sure if the pin did drop in but it’s not important in the old van as it’s heading for the scrap when I’ve got the bits off I need... I guess It’s a two man job getting the pin in... I can’t turn the crank that easilly as the gearbox is so messed up it’s driving the nearside wheel in neutral and I don’t have space or really need to remove the wheel on that side!

Again the timing pin didn’t go in at 2 o’clock but the holes forthe bolts lined up. My new T45 long bit was too wide to go through the holes in the sprocket so I had to trim it down with a grinder ...only had a 9” which made it fun.

Hope to get it all off when I get a couple more hours on it this weekend. I hope the new van’s timing pins line up!