Ford Workshop Service and Repair Manuals

Engine identification code

Engine code and engine serial number

On the 2.4L engine the engine code (4 digits) and the engine serial number (2 letters for the year and month and 5 figures for the serial number) are stamped in the cylinder block on the exhaust side (in line with cylinder No. 4).

If the engine or cylinder block is changed, the vehicle identification number must be stamped in the indicated location.

Engine identification plate

The engine identification plate is located on the cover of the timing cover. It contains the following data:

• date and time of manufacture
• engine part number

General

The 2.4L turbocharged engine uses the direct injection principle.

It is a 4-cylinder turbocharged diesel engine with two overhead camshafts and 16 valves.

The engine is available with various levels of power output:

• 55 kW/75 PS - without intercooling
• 66 kW/90 PS - with exhaust gas recirculation (EGR)
• 66 kW/90 PS - without EGR
• 85 kW/115 PS - with EGR
• 88 kW/120 PS - with EGR
• 88 kW/120 PS - without EGR
• 92 kW/125 PS - with EGR
• 101 kW/ 135 PS* - with EGR

* The engine is marketed as 135 PS, the actual power is 137 PS.

The valves are operated by rocker arms driven by two overhead camshafts.

The camshafts, together with the fuel injection pump, are driven by a twin timing chain from the crankshaft.

An EEC V Powertrain Control Module (PCM) is used for engine management. Diagnostics are carried out using FDS 2000 or WDS through the data link connector (DLC).

Both fuel injection pumps operate according to the "pilot injection" principle, which results in a reduction of the engine noise level.

Cylinder head

The valve cover incorporates the crankcase ventilation valve.

Rocker shafts

Camshafts and camshaft carrier

The intake and exhaust camshaft differ in the spacing between the cams.

Camshaft carrier

The upper mounting of the camshafts is provided by a camshaft carrier which incorporates five bearing caps.

The camshaft carrier is bolted flush to the cylinder head and secures the camshafts.

The shape of the camshaft carrier prevents incorrect installation. Before the camshaft carrier is installed, the mating faces on the underside of the camshaft carrier and the underside of the cylinder head must be cleaned thoroughly.

Cylinder head and valves

The cylinder head is made of aluminium and cannot be reworked.

Four valves per cylinder provides improved cylinder charging, a compact combustion chamber, and a vertical fuel injector which guarantees optimum distribution of the fuel in the combustion chamber.

Camshaft drive

The camshafts and the fuel injection pump are driven in the direction of the arrow by a timing chain (twin chain) from a the crankshaft sprocket.

When the timing chain is installed, the marked chain links must line up with the timing marks on the sprockets on the camshafts and the fuel injection pump.

Cylinder block and crankcase - overview

Connecting rods

The connecting rods are available in three different lengths. For identification, the large end and bearing cap are marked with the corresponding length code (H to J):

• H = 149.74 mm
• I = 149.80 mm
• J = 149.86 mm

Only connecting rods of the same length must be installed.

Pistons

To ensure optimum sealing of the cylinder, when installing the piston rings, make sure that the ring gaps are offset at 120 degrees to one another.

The locations on the piston skirt which come into contact with the cylinder bore incorporate molybdenum-coated surfaces. These counteract scoring of the cylinder and piston and therefore increase the life of the engine.

When installing a piston, make sure that the piston is installed in the correct position. The arrow on the piston crown and the mark on the piston skirt point towards the front of the engine.

The size of piston installed (skirt diameter code) matches the bore diameter code for the cylinder concerned.

Crankshaft

The crankshaft has induction-hardened journals which run in five bearings with clamped two-layer bearing shells.

The bearing caps are numbered (cylinder Nos. 2, 3 and 4) or marked with the letters “F” (front) or “R” (rear) and have an arrow which must point towards the front of the engine.

Cylinder block

The cylinder bores are machined directly in the block.

Three different bore diameters are used in production to ensure very precise adjustment of the clearance between the pistons and cylinders.

Once the bore diameter has been established, the optimum piston is installed. The pistons are also available in three different sizes in production.

Oil splash nozzles

Oil splash nozzles for piston cooling are installed under the cylinder bores between the crankshaft bearings.