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.
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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
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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: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.