Ford Workshop Service and Repair Manuals

Hole for alignment sleeve

Injector guide bushes

Oil duct

NOTE:When joining the two parts of the cylinder head, care must be taken to ensure that the oil supply bores are not closed off with sealant.

NOTE:Refer to the current service literature for the exact procedure and the correct tightening torques.

The upper and lower parts of the cylinder head are held exactly in position using two locating sleeves.

The cylinder head features top-entry intake ports.

The intake ports are on the right in the cylinder head (towards the rear of the engine when viewed from the rear of the vehicle) and the exhaust ports are on the left in the cylinder head (towards the front of the engine when viewed from the rear of the vehicle).

Guide bushes for the installation of the injectors are also located here.

The hydraulic tappets are connected to the oil circuit of the engine via the oil duct (3).

Both parts of the cylinder head are sealed using a one-component, silicone-based sealant when they are joined together.

Camshaft drive

Intake camshaft timing pulley

Bore for timing peg

Intake camshaft sprocket

Exhaust camshaft sprocket

Idler pulley

Bore for crankshaft timing peg

Coolant pump pulley

Tensioning pulley

Fuel pump timing pulley

Bore for timing peg

The intake camshaft is driven by the crankshaft via a timing belt. The exhaust camshaft is driven by the intake camshaft via a timing chain.

The timing belt has an automatic, spring loaded pulley tensioner.

The installation positions of the timing pulley on the intake camshaft and the timing pulley on the crankshaft are defined by a Woodruff key.

Special tools must be used for adjusting the valve timing. Refer to the current service literature for the exact procedure.

As is shown in the illustration, timing bores are located on the intake camshaft timing pulley, the crankshaft timing pulley and on the fuel pump timing pulley, and these need to be aligned with the respective opposite bores on the engine.

In this position the intake camshaft timing pulley, the crankshaft timing pulley and the fuel pump timing pulley are each secured by means of a timing peg (special tool).

Camshafts

Both camshafts run without additional bearing shells on five mountings in the upper part of the cylinder head.

The exhaust camshaft directly drives the vacuum pump, which engages in a groove on the connecting flange of the camshaft.

The sprockets are shrunk-fit onto the shaft spigots. Each of the two sprockets has two thrust surfaces for axial guidance of the camshafts.

The sprockets and thrust surfaces are made as a single component. The axial guidance of the camshafts is achieved by inserting the camshafts into the corresponding recesses in the upper part of the cylinder head.

Timing chain

Timing marks are stamped onto the camshaft sprockets in order to assist with the adjustment of the valve timing. During installation these marks must be brought into alignment with the marks on the timing chain links.

The installation position of the intake camshaft timing pulley is defined by a Woodruff key.

The timing chain tensioner should be inserted into the upper part of the cylinder head between the two runs of the timing chain before the camshafts are installed. It is not possible to install it at a later stage.

Timing chain tensioner

Timing chain tensioner

The timing chain tensioner comprises two halves which are pushed into each other during installation.

A spring is located between the two halves to provide the necessary tension for the timing chain.

For lubrication the timing chain tensioner is connected via an oil supply bore to the oil circuit of the engine.

Valves

The cylinder head is equipped with 4 valves per combustion chamber. The valve seats and guides are made of sintered steel.

The injectors are arranged centrally in the combustion chamber. The pencil-type glow plugs are located on the exhaust side (behind the engine when looking towards the front of the vehicle) and protrude laterally into the combustion chamber.

The valves are actuated via roller cam followers, and the adjustment of the valve clearance is performed via hydraulic tappets.

Cylinder block

Sequential engine serial number

VIN

Engine code

The engine identification is located on the exhaust side (between cylinders no. 1 and no. 2) on the cylinder block.

In addition, the VIN (vehicle identification number) and the engine code are located on the exhaust side on the transmission flange.

As a result of the revised bore and stroke in comparison to the 1.4L Duratorq TDCi (DV4) engine, the bore diameter and the cylinder block height have changed.

Pistons