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Transit 2006.5 (04.2006-)

Engine - 2.4L Duratorq-TDCi (Puma) Diesel - Engine Front Cover Transit 2006.5 (04/2006-)
In-vehicle Repair

Special Tool(s)

Lockin Tool, Flywheel

303-393

Separator, Oil Pan

303-428 (21-179)

Remover/Installer Crankshaft Front Oil Seal

303-679

Aligner, Front Cover

303-682

Holding Wrench, Crankshaft

303-1310
General Equipment
Spatula
Two M10 x 60 mm locating studs
Materials
Name
Specification
Sealer
WSE-M4G323-A4 

Removal

  1. Drain the cooling system. For additional information, refer to: (303-03 Engine Cooling)
    Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel/3.2L Duratorq-TDCi (Puma) Diesel, Vehicles With: Fuel Fired Booster Heater (General Procedures),
    Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel/3.2L Duratorq-TDCi (Puma) Diesel, Vehicles Without: Fuel Fired Booster Heater (General Procedures).
  1. Remove the cooling fan motor and shroud.
    For additional information, refer to: Cooling Fan Motor and Shroud (303-03 Engine Cooling, Removal and Installation).
  1. Remove the starter motor.
    For additional information, refer to: Starter Motor - 2.4L Duratorq-TDCi (Puma) Diesel/3.2L Duratorq-TDCi (Puma) Diesel (303-06 Starting System, Removal and Installation).

  1. Install the special tool.

  1. Detach the water pump and the brake vacuum pump from the engine and position them to one side (four bolts).
    • Discard the gasket.

  1. Detach the thermostat housing support bracket from the cylinder head and disconnect the radiator upper hose from the thermostat housing.

  1. Disconnect the coolant outlet connector from the engine.
    • Discard the O-ring seal.

  1. Remove the accessory drive belt idler pulley and the cooling fan pulley.

  1. Using the special tool, remove the crankshaft pulley.

  1. Using the special tool, remove the crankshaft front oil seal.
    • Discard the seal.

  1. Remove the engine front cover nuts and bolts.
    • 2 nuts.
    • 20 bolts.

  1. NOTE:
    NOTE:Lubricate the spatula with clean engine oil.
    NOTE:
    NOTE:Engine front cover can be distorted during removal.
    Using the special tool and a spatula, separate the engine front cover from the engine.
    • Insert the special tool between the engine front cover and the engine, slide the special tool counterclockwise, make enough room for the spatula and return the special tool to the original position.
    • Slide the spatula counterclockwise around the engine front cover, cutting the silicone gasket.
    • Remove and discard the engine front cover.

Installation

  1. Clean the mating faces of the engine and the engine front cover.
  1. Install two M10 x 60 mm locating studs to the cylinder block to aid installation of the engine front cover gasket.

  1. Install a new engine front cover gasket.

  1. CAUTION:
    CAUTION:Install the engine front cover within five minutes of applying the sealer.
    NOTE:
    NOTE:Install a new engine front cover.
    Apply a 3 mm diameter bead of sealer to the engine front cover.

  1. Using the special tool, install the engine front cover.
  1. Remove the locating studs.

  1. CAUTION:
    CAUTION:Install new M6 x 16 mm engine front cover bolts, if necessary.
    Install the engine front cover nuts and bolts.
    • 2 nuts.
    • 20 bolts.

  1. Install the engine front cover nuts and bolts.
    • 2 nuts.
    • 20 bolts.

  1. NOTE:
    NOTE:Install a new crankshaft front oil seal.
    NOTE:
    NOTE:A new crankshaft front oil seal is supplied with an alignment sleeve that will be pushed out during installation.
    Using the special tool, install the crankshaft front oil seal.

  1. Install the accessory drive belt idler pulley and the cooling fan pulley.

  1. Attach the thermostat housing support bracket to the cylinder head and connect the radiator upper hose to the thermostat housing.

  1. NOTE:
    NOTE:Install a new coolant outlet connector O-ring seal.
    Connect the coolant outlet to the engine.

  1. NOTE:
    NOTE:Install a new water pump gasket.
    Attach the water pump and brake vacuum pump to the engine (four bolts).

  1. CAUTION:
    CAUTION:Crankshaft pulley retaining bolts must only be used three times.
    NOTE:
    NOTE:Stamp the crankshaft pulley retaining bolt heads with a center punch to indicate usage.
    Using the special tool, install the crankshaft pulley.
    • Tighten the bolts in two stages.
    • Stage 1: 45 Nm.
    • Stage 2: 90 degrees.

  1. Remove the special tool.
  1. Install the starter motor.
    For additional information, refer to: Starter Motor - 2.4L Duratorq-TDCi (Puma) Diesel/3.2L Duratorq-TDCi (Puma) Diesel (303-06 Starting System, Removal and Installation).
  1. Install the cooling fan motor and shroud.
    For additional information, refer to: Cooling Fan Motor and Shroud (303-03 Engine Cooling, Removal and Installation).
  1. Fill and bleed the cooling system. For additional information, refer to: (303-03 Engine Cooling)
    Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel/3.2L Duratorq-TDCi (Puma) Diesel, Vehicles With: Fuel Fired Booster Heater (General Procedures),
    Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel/3.2L Duratorq-TDCi (Puma) Diesel, Vehicles Without: Fuel Fired Booster Heater (General Procedures).

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