| In-vehicle Repair Special Tool(s) | | Gauge, Bolt Angle 303-174 | General Equipment Materials Name Specification Metal surface cleaner 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 vapors are always present and may ignite. Failure to follow these instructions may result in personal injury. WARNING:Do not carry out any repairs to the fuel injection system with the engine running. The fuel pressure within the system is approximately 1600 bar. Failure to follow this instruction may result in personal injury. WARNING:Wait at least one minute after the engine stops before commencing any repair to the fuel injection system. Failure to follow this instruction may result in personal injury. CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness be observed when working with these components. Always install blanking plugs to any open orifices or lines. CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components to prevent foreign material entering the components. | | -
Remove the battery.
For additional information, refer to: Battery - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (414-01 Battery, Mounting and Cables, Removal and Installation).
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Remove the fuel filter.
For additional information, refer to: Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Water-in-Fuel Sensor (310-01A Fuel Tank and Lines, Removal and Installation) /
Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Water-in-Fuel Sensor (310-01A Fuel Tank and Lines, Removal and Installation).
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Remove the camshafts.
For additional information, refer to: Camshafts (303-01E Engine - 2.0L Duratorq-TDCi (DW) Diesel, In-vehicle Repair).
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Install the engine front mount bracket. | | | -
Loosely install the engine front mount using the engine front mount retaining nuts only. - Do not install new engine front mount retaining nuts at this stage.
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Remove the thermostat housing.
For additional information, refer to: Thermostat Housing (303-03E Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
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Remove the exhaust gas recirculation (EGR) cooler.
For additional information, refer to: Exhaust Gas Recirculation (EGR) Cooler (303-08D Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
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Remove the EGR valve.
For additional information, refer to: Exhaust Gas Recirculation (EGR) Valve (303-08D Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
| 10. Remove the components in the order indicated in the following illustration(s) and table(s). 1 - Timing belt rear cover retaining bolt 2 - Fuel filter bracket upper retaining bolt 3 - Fuel filter bracket lower retaining bolt 6 - Turbocharger intake pipe retaining bolt 7 - Turbocharger intake pipe flange bolts 8 - Turbocharger intake pipe 9 - Turbocharger intake pipe gasket 10 - Turbocharger vacuum hose 11 - Turbocharger outlet pipe retaining nut 12 - Turbocharger outlet pipe 13 - Catalytic converter bracket retaining nuts 15 - Turbocharger oil return line flange bolts 16 - Turbocharger oil return line 17 - Turbocharger oil return line gasket 18 - Turbocharger retaining bolt 19 - Turbocharger retaining nut 20 - Engine support insulator retaining bolt 21 - Exhaust manifold retaining nuts 22 - Exhaust manifold spacers 23 - Exhaust manifold heat shield 25 - Exhaust manifold gasket 11. To install, reverse the removal procedure. Removal Details Item 5 : Glow plug wiring harness | | -
Detach the glow plug wiring harness from the glow plugs. | Item 14 : Turbocharger oil supply line | | -
Remove the turbocharger oil supply line banjo bolt. - Discard the turbocharger banjo bolt seal.
| Item 24 : Exhaust manifold | | -
Move the engine 50 mm forwards until the exhaust manifold is clear of the exhaust manifold studs. | Item 26 : Engine front mount | | -
Using a trolley jack and a suitable wooden block under the oil pan raise the engine so that the engine front mount is free from load. | | | -
Remove the engine front mount. | | | -
Remove the engine front mount bracket. | Item 27 : Cylinder head bolts | | -
Remove the engine rear lifting eye. | | | -
Remove the cylinder head bolts in the sequence shown. | Installation Details Item 29 : Cylinder head gasket | | -
Check the cylinder head for distortion.
For additional information, refer to: Cylinder Head Distortion (303-00 Engine System - General Information, General Procedures).
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CAUTION:The thickness of the new cylinder head gasket must be the same as that of the old one (hole marked). Install a new cylinder head gasket. | Item 27 : Cylinder head bolts | | -
Using the special tool, install the cylinder head bolts. - Tighten the bolts in the sequence shown in two stages.
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Install the engine rear lifting eye. | Item 26 : Engine front mount | | -
Install the engine front mount bracket. | | | -
Install the engine front mount with the engine front mount nuts only. - Do not install new engine front mount retaining nuts at this stage.
| Item 24 : Exhaust manifold | | -
Move the engine 50 mm rearwards until the exhaust manifold is located on the exhaust manifold studs. | Item 14 : Turbocharger oil supply line | | -
NOTE:Install a new turbocharger oil supply line banjo bolt seal. Install the turbocharger oil supply line banjo bolt. | Item 5 : Glow plug wiring harness | | -
Attach the glow plug wiring harness to the glow plugs. | |
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