ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
Assembly|Installation > < Cylinder Head

Transit 2006.5 (04.2006-)

Engine - 2.4L Duratorq-TDCi (Puma) Diesel - Engine Transit 2006.5 (04/2006-)

Assembly

Special Tool(s)
205-044
Holding Fixture, Dial Indicator Gauge

205-069
Dial Indicator Gauge (Metric)

205-070
Holding Fixture, Dial Indicator Gauge

303-122
Lifting Bracket, Engine

303-1310
Holding Wrench, Crankshaft

303-254
Locking Tool, Flywheel

303-391
Setting Gauge, Crankshaft

303-432
Holding Fixture, Dial Indicator Gauge (Cylinder Liner Protrusion)

303-435
Mounting Stand

303-435-06
Mounting Bracket for 303-435

303-435-11B
Mounting Plate for 303-435-06

303-679
Remover/Installer, Engine Front Cover Inspection Plate

303-680
Socket, Cylinder Head Temperature Sensor

303-682
Aligner, Engine Front Cover

303-698
Timing Tool, Crankshaft

308-204
Aligner, Clutch Disc
Materials
Name
Specification
Engine Oil - 5W-30
WSS-M2C913-B
Silicone Sealant
WSE-M4G323-A4
General Equipment
6 mm drill bit
Piston ring compressor
Round-ended steel rule
  1. NOTE:
    NOTE:Make sure that these components are installed to the noted removal position.
    Material: Engine Oil - 5W-30

  1. Material: Engine Oil - 5W-30

  1. NOTE:
    NOTE:Make sure that these components are installed to the noted removal position.
    Torque:
    Stage 1:
    45 Nm
    Stage 2:
    80 Nm
    Stage 3:
    105°

  1. General Equipment: Piston ring compressor
    Material: Engine Oil - 5W-30

  1. NOTE:
    NOTE:Note the position of each component before removal.
    Material: Engine Oil - 5W-30

  1. NOTE:
    NOTE:Make sure that these components are installed to the noted removal position.
    Torque:
    Stage 1:
    30 Nm
    Stage 2:
    100°

  1. NOTE:
    NOTE:Only tighten the bolts finger tight at this stage.

  1. The ladder frame and the cylinder block must be aligned so that the side clearance does not exceed 0.05 mm overlap to 0.05 mm gap.
    Special Tool(s): 303-432

  1. The ladder frame and the cylinder block must be aligned so that the rear clearance does not exceed 0.01 mm overlap to 0.2 mm gap.
    General Equipment: Round-ended steel rule

  1. Torque: 23 Nm

  1. NOTE:
    NOTE: Only tighten the bolts finger tight at this stage.

  1. Take a reference measurement from the front face of the crankshaft sprocket.
    Special Tool(s): 205-044, 205-069

  1. Take measurements at two different points on the oil pump sprocket and align the oil pump sprocket.
    Special Tool(s): 205-044, 205-069

  1. Torque: 10 Nm

  1.  
    • A new crankshaft rear seal carrier is supplied with an alignment sleeve that must not be removed until the crankshaft rear seal is fully installed. Failure to follow this instruction may result in damage to the vehicle.
    • Clean the area on the engine before installing a new crankshaft rear seal carrier.
    • Check the two foam pads are located as shown on the ladder frame gasket.

  1.  
    • Install the new crankshaft rear seal carrier within five minutes of applying the recommended sealant. Failure to follow this instruction may result in damage to the vehicle.
    • Do not add any more than the specified quantity of sealant or add the sealant anywhere other than the area shown.
    • If the foam pads are not present on inspection, fill the square areas shown with 75% of sealant.
      Material: Silicone Sealant

  1. NOTE:
    NOTE:New crankshaft rear seal carriers are supplied with an alignment sleeve which must be removed after installation.
    Torque: 10 Nm

  1. CAUTION:
    CAUTION:Make sure that the flywheel is in full contact with the crankshaft flange before installing the flywheel bolts.
    Special Tool(s): 303-254
    Torque:
    Stage 1:
    50 Nm
    Stage 2:
    80 Nm
    Stage 3:
    112 Nm

  1. Special Tool(s): 205-069, 205-070

  1. NOTE:
    NOTE:Do not fully tighten the crankshaft position sensor bracket retaining bolts at this stage.

  1. NOTE:
    NOTE:After installation do not move the special tool.
    Special Tool(s): 303-391

  1. Rotate the crankshaft until piston No. one is approximately 10 mm before top dead center (TDC).
    Special Tool(s): 205-069, 205-070
  1. Zero the dial indicator gauge.

  1. Mark the position on the flywheel primary mass.
    Special Tool(s): 303-391

  1. NOTE:
    NOTE:Rotate the crankshaft counterclockwise.
    1. Rotate the crankshaft until the piston No. one achieves zero on the dial indicator gauge.
    1. Mark the position on the flywheel primary mass.
      Special Tool(s): 303-391
  1. Repeat the previous steps to make sure that the marking is correct.

  1. NOTE:
    NOTE:The middle of the markings is TDC.
    Measure the distance between the two marks.
  1. Divide the amount by two and mark the position TDC on the flywheel primary mass.

  1. Measure the circumference of the flywheel primary mass.
  1. Multiply the circumference by 0.1388 and mark the calculated amount on the flywheel primary mass by measuring from TDC counterclockwise.

  1.  
    1. First mark.
    1. Second mark.
    1. Determined TDC.
    1. Determined 50 degrees before top dead center (BTDC).

  1. CAUTION:
    CAUTION:Do not turn the crankshaft when the special tool is fully located into the flywheel. Failure to follow this instruction will cause damage to the CKP sensor hole.
    NOTE:
    NOTE:Rotate the crankshaft in the normal direction of rotation to the mark of the calculated 50 degrees BTDC.
    NOTE:
    NOTE:Make sure that the special tool is fully located in the flywheel so that the engine cannot be rotated in either direction.
    Install the special tool.
    Special Tool(s): 303-698

  1. Torque: 25 Nm

  1. Tighten the bolts two turns at a time.
    Special Tool(s): 308-204
    Torque: 29 Nm

  1. NOTE:
    NOTE:Measure the piston protrusion of each cylinder at top dead center (TDC).
    Measure the distance between the piston crown and the cylinder block at the points indicated.

  1. NOTE:
    NOTE:The largest measurement determines the choice of the cylinder head gasket.
    Using the special tools, measure the piston protrusion.
    Special Tool(s): 205-069, 205-070, 303-432
  1. Determine the cylinder head gasket.
    Refer to: Specifications (303-01A Engine - 2.3L Duratec-HE (MI4), Specifications).

  1. NOTE:
    NOTE:Install a new cylinder head gasket as determined in previous steps.

  1. Torque:
    Bolts 1 to 10 20 Nm
    Bolts 11 to 18 10 Nm
    Bolts 1 to 10 40 Nm
    Bolts 11 to 18 20 Nm
    Bolts 1 to 10 180°
    Bolts 11 to 18 180°

  1. Material: Silicone Sealant

  1. Torque:
    Bolts 1 to 22 23 Nm
    Bolts 23 to 24 10 Nm

  1. Torque:
    Stage 1:
    10 Nm
    Stage 2:
    30°

  1. Torque: 23 Nm

  1. Torque:
    1 64 Nm
    2 33 Nm

  1. Install the Special Tool(s): 303-698

  1. NOTE:
    NOTE:Make sure that the installation marks are aligned.
    General Equipment: 6 mm drill bit
    Torque: 33 Nm
  1. Remove the 6 mm drill bits.

  1. Torque: 15 Nm

  1. NOTE:
    NOTE:Make sure that a new component is installed.
    Torque: 15 Nm

  1. Remove the Special Tool(s): 303-698
  1. Rotate the engine two revolutions.

  1. Install the Special Tool(s): 303-698

  1. Check the position of the timing marks and correct if necessary.
    General Equipment: 6 mm drill bit
  1. Remove the 6 mm drill bits.

  1. Remove the Special Tool(s): 303-698

  1. NOTE:
    NOTE:Make sure that a new component is installed.
    Torque: 7 Nm

  1.  
    1. NOTE:
      NOTE:Make sure that a new component is installed.
      Torque: 10 Nm
    1. Torque: 10 Nm

  1. Using a socket (or similar), press the new fuel injector copper seals onto the fuel injectors making sure that the copper seals are pushed fully home to prevent uneven clamping.

  1. CAUTION:
    CAUTION:Make sure that new bolts are installed.
    Torque:
    Stage 1:
    6 Nm
    Stage 2:
    180°

  1. NOTE:
    NOTE:Make sure that a new component is installed.

  1. NOTE:
    NOTE:The component must be installed within 5 minutes of applying the sealant.
    NOTE:
    NOTE:Make sure that a new component is installed.
    Material: Silicone Sealant

  1. Special Tool(s): 303-682
    Torque:
    1 10 Nm
    2 11 Nm

  1. NOTE:
    NOTE:Make sure that a new component is installed.
    Special Tool(s): 303-679

  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.
    Special Tool(s): 303-1310
    Torque:
    Stage 1:
    45 Nm
    Stage 2:
    90°

  1. Install the following items:
    1. Torque: 48 Nm
    1. Torque: 48 Nm

  1. Torque:
    1 10 Nm
    2 23 Nm
    3 23 Nm

  1. Torque: 20 Nm

  1. Torque:
    1 10 Nm
    2 23 Nm

  1. Torque: 9 Nm

  1. Torque:
    1 6 Nm
    2 3 Nm

  1. Torque: 10 Nm

  1. Torque:
    Stage 1:
    6 Nm
    Stage 2:
    23 Nm

  1. Install the following items:
    1. NOTE:
      NOTE:Make sure that a new component is installed.
      NOTE:
      NOTE:Only tighten the nuts finger tight at this stage.
    1. NOTE:
      NOTE: Make sure that new components are installed.
      NOTE:
      NOTE:Only tighten the nuts finger tight at this stage.
    1. Torque: 15 Nm

  1. Torque: 35 Nm

  1. Torque: 23 Nm

  1. NOTE:
    NOTE:Make sure that a new component is installed.
    Special Tool(s): 303-680
    Torque: 11 Nm

  1. Torque: 23 Nm

  1.  
    1. Torque: 11 Nm
    1. Torque: 20 Nm

  1.  
    1. Torque: 23 Nm
    1. Torque: 40 Nm
    1. Torque: 23 Nm

  1.  
    1. Torque: 10 Nm
    1. Torque: 23 Nm
    1. Torque: 35 Nm

  1.  
    1. Torque: 8 Nm
    1. Torque: 12 Nm
    1. Torque: 35 Nm

  1. Material: Silicone Sealant

  1. Torque:
    Stage 1:
    7 Nm
    Stage 2:
    14 Nm

  1. Install the Special Tool(s): 303-122

  1. Remove the Special Tool(s): 303-435-06, 303-435

  1. Remove the Special Tool(s): 303-435-11B

  1. Torque: 22 Nm

  1.  
    1. Torque: 48 Nm
    1. Torque: 8 Nm

Assembly|Installation > < Cylinder Head