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Cylinder Head > < General Procedures|Removal and Installation|Disassembly|Engine

Ranger 2006.5 (05.2006-)

Engine - 2.5L Duratorq-TDCi (WL) Diesel/3.0L Duratorq-TDCi (WL) Diesel - Cylinder Block Ranger 2006.5 (05/2006-)
Disassembly and Assembly of Subassemblies

Special Tool(s)

Ring Gear Brake Set

49 E011 1A0

Pulley Puller

49 S019 215B

Oil Seal Installer

49 F027 009

Oil Seal Installer

49 S010 301

Oil Seal Installer

49 S011 103

Piston Pin Replacer

49 G011 001

1. Disassemble the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Oil drain plug
2
-
Oil pan
See Disassembly Detail
3
-
Oil strainer
4
-
Oil pipe

 
Item
Part Number
Description
5
-
Crankshaft pulley
See Disassembly Detail
6
-
Seal plate
7
-
Supply pump pulley
See Disassembly Detail
8
-
Timing gear cover
See Disassembly Detail
9
-
Oil pump
10
-
Supply pump gear
See Disassembly Detail
11
-
Timing gear
12
-
Supply pump
13
-
Timing gear case
See Disassembly Detail
14
-
Dual-mass flywheel
See Disassembly Detail
15
-
End plate
16
-
Rear cover
See Disassembly Detail
17
-
Seal plate
18
-
Oil pump cover
19
-
Driven gear
20
-
Plug
21
-
Plunger spring
22
-
Control plunger
23
-
Oil pump body

 
Item
Part Number
Description
24
-
Balance shaft
25
-
Connecting rod cap
See Disassembly Detail
26
-
Lower connecting rod bearing
27
-
Piston, connecting rod
See Disassembly Detail
28
-
Upper connecting rod bearing
29
-
Piston ring
30
-
Piston pin clip
31
-
Piston pin
See Disassembly Detail
32
-
Piston
33
-
Connecting rod
34
-
Main bearing cap
See Disassembly Detail
35
-
Lower main bearing, lower thrust bearing
36
-
Crankshaft
See Disassembly Detail
37
-
Upper main bearing, upper thrust bearing
38
-
Oil jet valve, nozzle
39
-
Cylinder block

2. Assemble the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Cylinder block
2
-
Oil jet valve, nozzle
3
-
Upper main bearing, upper thrust bearing
4
-
Crankshaft
5
-
Lower main bearing, lower thrust bearing
6
-
Main bearing cap
See Assembly Detail
7
-
Connecting rod
See Assembly Detail
8
-
Piston
9
-
Piston pin
10
-
Piston pin clip
11
-
Piston ring
See Assembly Detail
12
-
Upper connecting rod bearing
13
-
Piston, connecting rod
14
-
Lower connecting rod bearing
15
-
Connecting rod cap
16
-
Balance shaft

 
Item
Part Number
Description
17
-
Oil pump body
18
-
Control plunger
19
-
Plunger spring
20
-
Plug
21
-
Driven gear
See Assembly Detail
22
-
Oil pump cover
See Assembly Detail
23
-
Rear cover
See Assembly Detail
24
-
End plate
25
-
Dual-mass flywheel
See Assembly Detail
26
-
Seal plate, rear end
27
-
Timing gear case
See Assembly Detail
28
-
Supply pump
29
-
Timing gear
See Assembly Detail
30
-
Supply pump gear
31
-
Oil pump
32
-
Timing gear cover
See Assembly Detail
33
-
Supply pump pulley
See Assembly Detail
34
-
Seal plate, front end
35
-
Crankshaft pulley
See Assembly Detail

 
Item
Part Number
Description
36
-
Oil pipe
See Assembly Detail
37
-
Oil strainer
38
-
Oil pan
39
-
Oil drain plug
See Assembly Detail

Disassembly Details

Item 2 : Oil pan
  1. Remove the oil pan using a separator tool.

Item 5 : Crankshaft pulley
  1. Remove the crankshaft pulley using the SST.

Item 7 : Supply pump pulley
  1. Remove the supply pump pulley using the SST.

Item 8 : Timing gear cover
  1. Remove the timing gear cover using a separator tool.

  1. Remove the oil seal using a screwdriver protected with a rag.

Item 10 : Supply pump gear

  1. Set the No.1 cylinder to TDC of compression.

  1. Rotate the flywheel ring gear from TDC to approximately 30°BTDC (about 13 teeth on the gear).

  1. NOTE:
    NOTE:If the chip cut gear is hard to find, move the supply pump gear on notch back and forth, then check the chip cut gear.
    Verify that the end-gap (V groove) of the timing gear case and the chip cut gear of the fuel injection pump gear are aligned.

  1. WARNING:
    WARNING:When removing the supply pump gear, be sure to secure the scissors gear to the supply pump gear using a lock bolt (M6×1.0; length under the bolt head is approximately 16 mm {0.63 in}). Otherwise, the scissors gear will rotate with the spring force, causing personal injury.
    CAUTION:
    CAUTION:When removing the supply pump gear, be sure to secure the scissors gear to the supply pump gear using a look bolt (M6×1.0; length under the bolt head is approximately 16 mm {0.63 in}) to prevent the scissors gear form rotating with the spring force. Otherwise, the scissors gear will not align with the supply pump gear, and the supply pump gear with the scissors gear will not engage with the idler gear.
    NOTE:
    NOTE:The supply pump gear with a scissors gear has a lock bolt hole.
    Fix the scissors gear to the supply pump gear using a lock bolt (M6×1.0; length under the bolt head is approximately 16 mm {0.63 in}).

  1. Hold the crankshaft using the SST and loosen the gear nut.

  1. Remove the supply pump gear using the SST and bolt (M6X1.0, Length 30mm {1.18 in}).

Item 13 : Timing gear case
  1. Remove the timing gear case using the separator tool.

Item 14 : Dual-mass flywheel
  1. Remove the Dual-mass flywheel using the SST.

Item 16 : Rear cover
  1. Remove the oil seal using a screwdriver protected with a rag.

Item 25 : Connecting rod cap

  1. Before removing the connecting rod cap, inspect the connecting rod side clearance. (
    For additional information, refer to: Connecting Rod Bearing Journal Clearance (303-00 Engine System - General Information, General Procedures).

Item 27 : Piston, connecting rod

  1. Before removing the piston and connecting rod, inspect the connecting rod oil clearance.
    For additional information, refer to: Connecting Rod Bearing Journal Clearance (303-00 Engine System - General Information, General Procedures).
    303-00 G904213
  1. Inspect the oscillation torque.
    For additional information, refer to: Piston Inspection (303-00 Engine System - General Information, General Procedures).

Item 31 : Piston pin
  1. Remove the piston pin using the SST.

Item 34 : Main bearing cap

  1. Before removing the main bearing cap, inspect the crankshaft end play.
    For additional information, refer to: Crankshaft End Play (303-00 Engine System - General Information, General Procedures).

  1. Loosen the main bearing cap bolts in two or three steps in the order shown in the figure.

Item 36 : Crankshaft

  1. Before removing the crankshaft, inspect the main journal oil clearance.
    For additional information, refer to: Crankshaft Main Bearing Journal Clearance (303-00 Engine System - General Information, General Procedures).

Assembly Details

Item 6 : Main bearing cap

  1. Apply clean engine oil to the bolt threads and seat faces of the lower cylinder block bolts.

  1. Tighten the bolts in two or three steps in the order shown in the figure.
    1. Tightening procedure

        2. 1. (1) 14.5—34.5 Nm {1.5—3.5 kgf·m, 11—25 ft·lbf}.

        2. (2) 74.0—82.0 Nm {7.6—8.3 kgf·m, 55—60 ft·lbf}.

        3. (3) Loosen all the bolts (until bolts are torque-free).

        4. (4) 14.5—34.5 Nm {1.5—3.5 kgf·m, 11—25 ft·lbf}.

        5. (5) 42.5—45.5 Nm {4.4—4.6 kgf·m, 32—33 ft·lbf}.
  1. Put a paint mark on each bolt head.

  1. Using the marks as a reference, tighten the bolts by turning each 90°—105°as in Step 2.

Item 7 : Connecting rod

  1. Install one piston pin clip.

  1. Assemble the piston and connecting rod in the direction indicated in the figure.
  1. Apply clean engine oil to the piston pin.
  1. Install the piston pin until the pin contacts the clip as shown. If the pin cannot be installed easily, heat the piston.
  1. Insert the piston and connecting rod assembly into the cylinder with the F mark facing the front of the engine.
  1. Tighten the connecting rod cap bolts in two or three steps.
    1. Tightening torque 46.5—51.5 Nm {4.8—5.2 kgf·m, 34.3—37.9 ft·lbf}.
  1. Put a paint mark on each bolt.

  1. Using the marks as a reference, tighten the bolts by turning each 82.5°—97.5°.

Item 11 : Piston ring

  1. Install the oil ring.

  1. Install the second ring with R mark side upward.
  1. Install the top ring with tapered face side upward.

Item 22 : Oil pump cover
  1. Tighten the bolts in two or three steps in the order shown in the figure.

Item 23 : Rear cover

  1. Apply soapy water along the perimeter of the new oil seal.
  1. Push the oil seal slightly in by hand.

  1. Tap the oil seal in evenly using the SST and a hammer.
  1. To ensure that the oil seal is installed correctly, measure the distance between the end of the rear cover and the face of the oil seal.
    1. Rear oil seal press-in amount 0—0.5 mm {0—0.01 in}.

  1. Apply silicone sealant to the rear cover as shown.
    1. Thickness 2.0—3.0 mm {0.07—0.12 in}.

  1. Apply silicone sealant to the rear cover as shown in the figure.
    1. Thickness 2.0—3.0 mm {0.07—0.12 in}.
  1. Install the end plate.

Item 25 : Dual-mass flywheel

  1. Hold the crankshaft using the SST.

  1. Tighten the bolts in the order shown in the figure.

Item 27 : Timing gear case

  1. Install the new O-ring.

  1. Apply silicone sealant to the timing gear case as shown in the figure. Do not apply sealant to the O-ring.
    1. Thicknessf2.0—3.0 mm {0.07—0.12 in}

  1. Tighten the bolts in two or three steps in the order shown in the figure.

Item 29 : Timing gear
  1. Put a paint mark on the chip cut gear of the supply pump gear.

  1. Put a paint mark on the 10th and 11th teeth of the helical gear counting clockwise from the chip cut gear

  1. Verify that the 10th and 11th teeth of supply pump gear (helical gear) and the teeth of the scissors gear are aligned, then put a paint mark on the scissors gear.
  1. Set the No.1 cylinder to TDC of compression.

  1. Rotate the flywheel ring gear from TDC to approximately 30°BTDC (13 teeth on the gear).
  1. NOTE:
    NOTE:The helical gears except for the supply pump gear have a punch mark as the timing mark. The timing mark of each gear can be aligned easily if the paint mark is made on the punch mark.
    Align the timing marks. For the supply pump gear, align the timing mark as shown in the figure (View A).

  1. Remove the lock bolt.

  1. Tighten the bolts using the SST.

Item 32 : Timing gear cover

  1. Apply soapy water along the perimeter of the new oil seal.
  1. Push the oil seal slightly in by hand.

  1. Tap the oil seal in evenly using the SST and a hammer.
  1. To ensure that the oil seal is installed correctly, measure the distance between the end of the timing gear cover and the face of the oil seal.
    1. Front oil seal press-in amount 0.0—0.40 mm {0.0—0.015 in}.
    1. Fuel injection pump oil seal press-in amount 0.0—0.40 mm {0.0—0.015 in}.

  1. Apply silicone sealant to the timing gear cover as shown.
    1. Thickness f 2.0—3.0 mm {0.079—0.118 in}.

  1. Tighten the bolts in two or three steps in the order shown in the figure.

Item 33 : Supply pump pulley
  1. Install the supply pump pulley using the SST.

Item 35 : Crankshaft pulley
  1. Install the crankshaft pulley using the SST.

Item 36 : Oil pipe
  1. Tighten the bolts in two or three steps in the order shown in the figure.

Item 39 : Oil drain plug
  1. Apply silicone sealant to the oil pan as shown in the figure.
    1. Thicknessf2.0—3.0 mm {0.07—0.12 in}.

  1. CAUTION:
    CAUTION:If the bolts are reused, remove the old sealant from the bolt threads. Tightening a bolt that has old sealant on it can cause bolt hole damage.
    Tighten the oil pan bolts A as shown in the figure.
  1. Tighten the remaining oil pan bolts in several passes.

Cylinder Head > < General Procedures|Removal and Installation|Disassembly|Engine