Ford Transit 2002 Owner's Manual page 861

Fuel pump fuel supply
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CAUTION: The fuel system on this vehicle is designed to prevent the fuel tank being
run dry. When the fuel tank reaches a preset limit after the low fuel warning indicator has
been illuminated, the engine will be made to run rough to indicate very low fuel level.
Failure to refill the fuel system at this time, will result in damage to the fuel injection
components if the fuel system is allowed to run dry.
The fuel filter element in the common rail fuel system is designed to extract far smaller
particles from the fuel supply than conventional fuel filters.
To aid with the rapid warm up of the fuel supply to the fuel pump, the fuel filter is fitted
with a temperature conscious fuel return bypass valve.
At temperatures below 50°C, the bypass valve is fully open and the majority of the
returned fuel is circulated through the fuel filter and back to the fuel pump.
When the fuel temperature in the fuel filter has reached a temperature above 50° C, the fuel
return bypass valve closes and the returned fuel is delivered back to the fuel tank.
The return fuel cannot be allowed to continue to circulate through the fuel filter after 50°C
as the temperatures produced by compressing the fuel to such high pressures would cause
the fuel to overheat. When the fuel is returned to the fuel tank, the fuel line which transfers
the fuel along the underbody, cools the fuel sufficiently to prevent overheat concerns.
High-pressure fuel pump
Description
Fuel pump fuel return line connection
Fuel tank fuel supply line connection
Fuel pump fuel supply line connection
Filter element
Filter drain screw
Bimetallic fuel return sensor
Fuel return bypass valve
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