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Ford TransitTourneo Connect Workshop Service and Auto Repair Manuals

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Engine - Vehicles Without: Common Rail Fuel Injection > < In-vehicle Repair|Engine

TransitTourneo Connect 20025 (062002-) Engine Removal - Common Rail Fuel Injection

Engine - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel - Engine—Vehicles With: Common Rail Fuel Injection Transit/Tourneo Connect 2002.5 (06/2002-)
Disassembly

Special Tool(s)

Slide Hammer

205-047 (15-011)

Universal Flange Holding Wrench

205-072 (15-030A)

Locking Tool, Flywheel

303-393 (21-168)

Remover/Installer, Hose Clamp

303-397 (24-003)

Mounting Stand

303-435 (21-187)

Mounting Bracket for 303-435

303-435-06 (21-031B)

Adapter for 205-047

303-633 (21-227)

Remover, Camshaft Sprocket

303-651 (21-229)

Remover, Fuel Injection Pump Pulley

310-095 (23-067)
General Equipment
Engine vacuum cleaner
CAUTION:
CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always fit blanking plugs to any open orifices or lines.
CAUTION:
CAUTION:Do not disassemble or clean inside the fuel injection supply manifold, even with an ultrasonic cleaner.
  1. Using the special tool, attach the engine to the mounting stand.
    • Attach the mounting bracket.
    • Mount the engine on the mounting stand.
  1. Drain the engine oil.
    • Allow the oil to drain into a suitable container.

  1. Detach the turbocharger oil supply tube from the turbocharger.
    • Discard the sealing washers.

  1. Remove the turbocharger oil supply line.
    • Discard the sealing washers.

  1. Detach the turbocharger oil return tube.
    • Discard the O-ring seal.

  1. Remove the oil filter.
    • Discard the filter.

  1. Remove the oil cooler.
    • Discard the gasket.

  1. Using the special tool, detach the positive crankcase ventilation (PCV) hoses from the lower PCV pipe.

  1. Using the special tool, detach the PCV hoses from the valve cover.

  1. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
    1. Detach the electrical connector from the PCV housing.
    1. Disconnect the electrical connector.

  1. Remove the PCV housing.

  1. Using the special tool, detach the PCV hose from the brake booster vacuum pump.

  1. Remove the brake booster vacuum pump.
    • Discard the O-ring seal.

  1. CAUTION:
    CAUTION:Carry out the fuel injection component cleaning procedure before carrying out any repairs to fuel injection system components to prevent foreign material entering the components.
    Detach the fuel injector return line from the fuel injectors.

  1. Remove the fuel injector return line.

  1. CAUTION:
    CAUTION:Carry out the fuel injection component cleaning procedure before carrying out any repairs to fuel injection system components to prevent foreign material entering the components.
    Disconnect the fuel injector electrical connectors.

  1. Disconnect the camshaft position (CMP) sensor electrical connector.

  1. Disconnect the oil pressure switch electrical connector.

  1. Detach the oil level indicator tube bracket from the thermostat housing.

  1. Detach the glow plug wiring harness bracket from the oil level indicator tube bracket.

  1. Disconnect the knock sensor (KS) electrical connector.

  1. Disconnect the high-pressure fuel sensor electrical connector from the fuel injection supply manifold.

  1. Disconnect the fuel pump electrical connectors.

  1. NOTE:
    NOTE:Make a note of the orientation of the clamps to make sure they are positioned in exactly the same position when installed.
    Remove the high-pressure fuel supply line clamps.

  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply lines remain in contact with the fuel injectors until all unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    CAUTION:
    CAUTION:Cap the fuel injectors to prevent dirt ingress.
    Detach the high-pressure fuel supply lines from the fuel injectors.

  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply lines remain in contact with the fuel injection supply manifold until all unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    CAUTION:
    CAUTION:Cap the fuel injection supply manifold to prevent dirt ingress.
    Detach the high-pressure fuel supply lines from the fuel injection supply manifold.
  1. Using the engine vacuum cleaner, vacuum foreign material from the high-pressure fuel supply lines and the fuel injection supply manifold.
  1. Remove the high-pressure fuel supply lines.
    • Discard the fuel lines.

  1. Remove the high-pressure fuel supply line clamp retaining nut.

  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply lines remain in contact with the fuel pump and the fuel injection supply manifold until all unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    Detach the high-pressure fuel supply line and clamp from the fuel pump and the fuel injection supply manifold.
  1. Using the engine vacuum cleaner, vacuum foreign material from the high-pressure fuel supply line, the fuel pump and the fuel injection supply manifold.
  1. Remove the high-pressure fuel supply line.

  1. NOTE:
    NOTE:Make a note of the orientation of the clamps to make sure it is positioned in exactly the same position when installed.
    Remove the clamp from the high-pressure fuel supply line.
    • Discard the high-pressure fuel supply line.
  1. Using the engine vacuum cleaner, vacuum foreign material from the fuel pump and the fuel injection supply manifold.
  1. Install blanking caps to the open threaded ports on the fuel pump and the fuel injection supply manifold.

  1. Remove the fuel injectors.
    • Discard the bolts.

  1. Remove the fuel injection supply manifold.

  1. Remove the fuel injection supply manifold retaining bracket.

  1. Using the special tool, detach the coolant hose from the thermostat housing.

  1. Remove the timing belt cover.

  1. Detension the timing belt.
    • Loosen the timing belt tensioner bolt.
  1. Remove the timing belt.
    • Discard the timing belt.

  1. Remove the timing belt tensioner.

  1. Using the special tool, remove the camshaft pulley retaining bolt.

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

  1. Using the special tool, remove the fuel pump pulley.

  1. Remove the fuel pump oil seal retainer.
    • Discard the seal.

  1. Remove the timing belt rear cover.

  1. Remove the valve cover.

  1. Remove the oil baffle.

  1. CAUTION:
    CAUTION:Remove the cylinder head bolts in the sequence shown.
    Remove the cylinder head.
    • Discard the gasket and the bolts.

  1. Remove the engine front mount bracket.

  1. Using the special tool, remove the water pump pulley (four bolts).

  1. Remove the water pump.
    • Discard the gasket.

  1. Using the special tool, remove the crankshaft pulley.
    • Discard the bolt.

  1. Remove the accessory drive belt idler.

  1. Remove the timing chain housing cover.
    • Discard the gasket.

  1. Remove the timing chain tensioner.

  1. Detach the fuel pump sprocket.

  1. Remove the timing chain, sprockets and guides.

  1. Remove the fuel pump bracket.

  1. Remove the fuel pump.
    • Discard the gasket.

  1. Using the special tool, detach the upper coolant hose from the coolant distribution pipe.

  1. Remove the coolant distribution pipe.

  1. Remove the fuel pump bracket.

  1. CAUTION:
    CAUTION:Loosen the clutch pressure plate retaining bolts by two turns at a time in the sequence shown.
    Remove the clutch disc and pressure plate.

  1. Using the special tool, remove the dual mass flywheel.
    • Discard the bolts.

  1. Remove the crankshaft position (CKP) sensor.
    • Discard the sensor.

  1. Remove the oil pan retaining nuts and bolts (16 bolts, two nuts).

  1. Using the special tools, remove the oil pan.

  1. Remove the CKP sensor retaining bracket.

  1. Remove the crankshaft rear oil seal retainer.
    • Discard the retainer.

  1. Remove the oil pump connecting pipe.
    • Discard the O-ring seals.

  1. Remove the oil pump pickup tube.
    • Discard the O-ring seal.

  1. Remove the air conditioning (A/C) compressor retaining bracket.

  1. Remove the ladder frame (14 bolts).
    • Discard the gasket.

  1. Remove the timing chain rear housing.
    • Discard the gasket.

  1. NOTE:
    NOTE:Keep the connecting rod bearings and bearing caps in order for installation.
    Remove the pistons.

  1. NOTE:
    NOTE:Keep the main bearings and main bearing caps in order for installation.
    Remove the crankshaft.

Engine - Vehicles Without: Common Rail Fuel Injection > < In-vehicle Repair|Engine