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In-vehicle Repair|Oil Pan > < Exhaust Manifold

Transit 2000.5 (01.2000-05.2006)

Engine - 2.3L DOHC-16V - Cylinder Head Transit 2000.5 (01/2000-05/2006)
In-vehicle Repair

Special Tool(s)

Socket, Cylinder Head Bolt

303-392 (21-167)
Materials
Name
Specification
Loctite 7070
 

Removal

WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
All except vehicles with LPG fuel system
  1. Release the fuel system pressure. For additional information, refer to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
Vehicles with LPG fuel system
  1. Evacuate the fuel line. For additional information, refer to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
All vehicles
  1. Drain the cooling system. For additional information, refer to Section  303-03 Engine Cooling.
  1. Remove the throttle body. For additional information, refer to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls / 303-04G Fuel Charging and Controls.

  1. Disconnect the exhaust manifold to exhaust gas recirculation (EGR) valve tube from the exhaust manifold.

  1. Detach the exhaust manifold to EGR valve tube from the cylinder head.

  1. Detach the catalytic converter from the exhaust manifold.
    • Discard the gasket and retaining nuts.

  1. Using the special tool, disconnect the coolant hose from the thermostat housing.
Vehicles with LPG fuel system
  1. Disconnect the engine wiring harness electrical connector.

  1. Detach the engine wiring harness electrical connectors from the retaining bracket.
All except vehicles with LPG fuel system
  1. Disconnect the engine wiring harness electrical connector.

  1. Detach the engine wiring harness electrical connector from the retaining bracket.
All vehicles
  1. Disconnect the fuel injector electrical connectors.

  1. Disconnect the positive crankcase ventilation (PCV) hose from the valve cover.

  1. Remove the idle air control (IAC) valve.

  1. Disconnect the PCV hose from the intake manifold.

  1. Disconnect the exhaust gas recirculation (EGR) valve tube from the intake manifold.

  1. Detach the power steering pump (shown from below vehicle) bracket from the intake manifold.
  1. Remove the accessory drive belt. For additional information, refer to Section  303-05 Accessory Drive.

  1. Detach the generator from the generator bracket.
    • Remove the retaining bolts.
    • Lay the generator to one side.
Vehicles with LPG fuel system
  1. Disconnect the LPG fuel injection supply manifold hoses.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Disconnect the oil cooler hoses.
    • Allow the fluid to drain into a suitable container.
  1. Lower the vehicle.
All vehicles
  1. Remove the fuel supply and return lines retaining bracket.

  1. Remove the intake manifold (engine shown removed for clarity).
    • Discard the gasket.
  1. Remove the camshafts.
    For additional information, refer to Camshafts in this section.

  1. Disconnect the engine ground cable from the cylinder head.

  1. Remove the oil level indicator and tube.

  1. Disconnect the EGR sensor electrical connector.

  1. CAUTION:
    CAUTION:Do not remove the cylinder head bolts until the cylinder head has cooled to below 30°C.
    Remove the front three cylinder head bolts.

  1. CAUTION:
    CAUTION:Remove the cylinder head bolts in the sequence shown.
    Using the special tool, remove the cylinder head.
    • Guide the timing chain through the cylinder head and secure it to the engine front cover.
    • Discard the gasket.

Installation

All vehicles
  1. Clean the mating faces of the cylinder head and cylinder block with Loctite 7070.
  1. Check the cylinder head for distortion. For additional information, refer to Section  303-00 Engine System - General Information.

  1. CAUTION:
    CAUTION:Do not reuse the cylinder head bolts if the length is more than 174.3 mm.
    Measure the cylinder head bolts.

  1. CAUTION:
    CAUTION:Do not install the front three cylinder head bolts at this stage.
    CAUTION:
    CAUTION:Install new cylinder head bolts as necessary.
    NOTE:
    NOTE:Install a new cylinder head gasket.
    NOTE:
    NOTE:Guide the timing chain through the cylinder head
    Using the special tool, install the cylinder head.
    • Tighten the bolts in the sequence shown in four stages.
    • Stage 1: Tighten bolts 1 through 10 to 10 Nm.
    • Stage 2: Tighten bolts 1 through 10 to 35 Nm.
    • Stage 3: Tighten bolts 1 through 10 to 90 degrees.
    • Stage 4: Tighten bolts 1 through 10 to 90 degrees.

  1. Install the front three cylinder head bolts.

  1. Connect the engine ground cable to the cylinder head.
  1. Install the camshafts.
    For additional information, refer to Camshafts in this section.

  1. Connect the EGR sensor electrical connector.

  1. Install the oil level indicator and tube.

  1. NOTE:
    NOTE:Install a new intake manifold gasket.
    Install the intake manifold.
Vehicles with LPG fuel system
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Connect the oil cooler hoses.
  1. Lower the vehicle.
All vehicles
  1. Install the fuel supply and return lines retaining bracket.

  1. Attach the generator to the generator bracket.
  1. Install the accessory drive belt. For additional information, refer to Section  303-05 Accessory Drive.

  1. Attach the power steering pump (shown from below vehicle) bracket to the intake manifold.

  1. Connect the EGR valve tube to the intake manifold.

  1. Connect the PCV hose to the intake manifold.

  1. Install the IAC valve.

  1. Connect the PCV hose to the valve cover.
All except vehicles with LPG fuel system
  1. Attach the engine wiring harness electrical connector to the retaining bracket.

  1. Connect the engine wiring harness electrical connector.
Vehicles with LPG fuel system
  1. Attach the engine wiring harness electrical connectors to the retaining bracket.

  1. Connect the engine wiring harness electrical connector.

  1. Connect the LPG fuel injection supply manifold hoses.
All vehicles
  1. Connect the fuel injector electrical connectors.

  1. NOTE:
    NOTE:Install a new gasket and new retaining nuts.
    Attach the catalytic converter to the exhaust manifold.

  1. Connect the exhaust manifold to EGR valve tube to the exhaust manifold.

  1. Attach the exhaust manifold to EGR valve tube to the cylinder head.

  1. Using the special tool, connect the coolant hose to the thermostat housing.
  1. Install the throttle body. For additional information, refer to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls / 303-04G Fuel Charging and Controls.
  1. Fill and bleed the cooling system. For additional information, refer to Section  303-03 Engine Cooling.

In-vehicle Repair|Oil Pan > < Exhaust Manifold