Description and Operation
The Duratorq-TDCi diesel engine, which is available as a 66kW (90PS) version, is based on the familiar Endura-DI diesel engine, but has been brought to the latest state of the technology with a high-pressure fuel supply manifold.
This engine therefore complies with EEC emissions standard Stage III and all other requirements made on latest generation assemblies with regard to fuel consumption, quiet running, flexibility and power output.
The engine code for the Duratorq-TDCi is:
- 66 kW / 90 PS - HCPA (Stage III / LDT 2)
- 66 kW / 90 PS - HCPB (Stage III Car / LDT 1)
- 66 kW / 90 PS - HCPC (Stage I)
Location of the engine code on the cylinder block of the Duratorq-TDCi engine:
The five main bearing crankshaft has thrust half rings on the third main bearing that control the crankshaft end float.
Crankshaft timing sprocket
The crankshaft timing sprocket drives the injection pump sprocket by means of a chain drive.
Timing belt drive
Injection pump timing pulley
The camshaft timing belt is driven by the injection pump pulley and transmits the valve timing to the overhead camshaft.
CAUTION:Because a new timing belt stretches considerably when it is first installed, the instructions for adjustment must be followed exactly.
The tension of the timing belt is maintained by an automatic timing belt tensioner.
The timing pulley is retained on the camshaft by a taper. The required frictional force is applied to the camshaft by a central bolt.
Valve tappet, adjusting shims
The camshaft timing is transmitted to the valve springs by eight bucket tappets.
CAUTION:The lettering must face the tappets when the adjusting shims are installed.
Adjusting shims are available for adjusting the valve clearance. The thickness of these is indicated on the underside.
Identification of gasket thickness
Cylinder head gaskets of various thicknesses are available. Dependent on the piston projection, a certain thickness is assigned to the engine. This is indicated by indentations on the cylinder head gasket.
CAUTION:Thoroughly clean the gasket and mating faces. Do not use any sharp object for cleaning.
The cylinder head gasket is an MLS (multi-layered steel) gasket. The gasket consists of three steel layers. The steel layers have an outer covering of rubber. Because of this design, the longevity of the gasket is increased, and because the gasket does not settle during installation, the cylinder head bolts can be inserted with lower clamping force. However, because of the rubber surface, the gasket is also more susceptible to grooves, and therefore it must be cleaned without using sharp objects.
Crankshaft oil seals
NOTE:The rear crankshaft oil seal is supplied with an oil seal carrier. It must be aligned using the tool shown.
CAUTION:If the support ring is removed too soon, the oil seal will be compressed and made unusable.
The front and rear oil seals are made of PTFE and must be free from oil when installed.
Both oil seals are supplied with a support ring as a spare part. This must not be removed until after assembly, when it may drop out of the oil seal of its own accord.
The crankcase ventilation valve is located on the top of the cylinder head cover. To ensure optimal engine performance, this valve and all PCV hoses must be free of contaminants at all times.
The oil pan is made of steel. It is sealed using silcone based sealant (WSE-M4G-323-A6).
CAUTION:When removing the engine front mount, do not place a workshop jack under the oil pan to support the engine.
CAUTION:Support the engine and transmission on wooden blocks on the subframe/oil pan flange, so that the oil pan is not under load.
The oil pan will be pushed in if the engine is supported on a workshop jack. This can cause the oil supply to the oil intake pipe to be obstructed.
The oil drain plug is provided with an O-ring seal, and can be re-used many times.