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Transit 2000.5 (01.2000-05.2006)

Engine - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel - Camshafts Transit 2000.5 (01/2000-05/2006)
In-vehicle Repair

Special Tool(s)

Timing Tool, Crankshaft TDC

303-675

Timing Tool, Crankshaft

303-698
General Equipment
Three 6 mm drill bits
Materials
Name
Specification
Loctite 7070
 
Loctite 510
WSK-M2G348-A7 

Removal

  1. Remove the valve cover. For additional information, refer to: (303-01A Engine - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel)
    Valve Cover - 75 PS/90 PS (In-vehicle Repair),
    Valve Cover - 120 PS (In-vehicle Repair),
    Valve Cover - 135 PS (In-vehicle Repair).
  1. Remove the engine front cover. For additional information, refer to: (303-01A Engine - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel)
    Engine Front Cover - 75 PS (In-vehicle Repair),
    Engine Front Cover - 90 PS/120 PS (In-vehicle Repair).
  1. Remove the crankshaft position (CKP) sensor.
    For additional information, refer to: Crankshaft Position (CKP) Sensor - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (303-14 Electronic Engine Controls, Removal and Installation).

  1. Remove the rocker shafts.
    • Discard the bolts.

  1. Detension and lock the timing chain tensioner.
    1. Retract the pawl.
    1. Push the lock in.
    1. Insert a pin.

  1. Remove the timing chain tensioner and the right-hand timing chain guide.

  1. Remove the timing chain upper guide.

  1. Remove the camshaft sprockets and the timing chain.

  1. CAUTION:
    CAUTION:Remove the camshaft carrier bolts in the sequence shown.
    Remove the camshaft carrier.
  1. Remove the camshafts.

Installation

All vehicles
  1. Clean the mating faces of the camshaft carrier and the cylinder head.
Vehicles without common rail fuel injection
  1. Turn engine to 50 degrees before top dead center (TDC) and insert the special tool through the CKP sensor hole.
Vehicles with common rail fuel injection
  1. Turn engine to 50 degrees before top dead center (TDC) and insert the special tool through the CKP sensor hole.
All vehicles
  1. Apply a 2.5 mm diameter bead of Loctite 510 to the mating face of the cylinder head.
  1. Install the camshafts.

  1. Install the camshaft carrier.
    • Tighten the bolts in the sequence shown in two stages.
    • Stage 1: Tighten bolts 1 through 22 to 23 Nm.
    • Stage 2: Tighten bolts 23 through 25 to 10 Nm.

  1. Install the timing chain tensioner and the right-hand timing chain guide.

  1. CAUTION:
    CAUTION:The copper links of the timing chain must align with the timing marks on the camshaft sprockets.
    Install the camshaft sprockets and the timing chain.

  1. Insert 6 mm drill bits through the holes in the camshaft sprockets and tighten the camshaft sprocket retaining bolts finger tight.

  1. Install the timing chain upper guide.

  1. Loosen the fuel injection pump sprocket retaining bolts.

  1. CAUTION:
    CAUTION:The copper link of the timing chain must align with the timing mark on the fuel injection pump sprocket.
    Insert a 6 mm drill bit through the hole in the fuel injection pump sprocket and tighten the fuel injection pump sprocket retaining bolts finger tight.

  1. NOTE:
    NOTE:Make sure the timing chain tensioner is completely released.
    Unlock the timing chain tensioner by removing the pin.

  1. Tighten the camshaft sprocket and fuel injection pump sprocket retaining bolts.

  1. Remove the drill bits from the holes in the camshaft sprockets and fuel injection pump sprocket.
Vehicles without common rail fuel injection
  1. Remove the special tool from the CKP sensor hole.
Vehicles with common rail fuel injection
  1. Remove the special tool from the CKP sensor hole.
All vehicles

  1. NOTE:
    NOTE:Install new rocker shaft retaining bolts.
    NOTE:
    NOTE:The oil supply holes in the rocker shafts must point downwards.
    Install the rocker shafts.
    • Tighten the bolts in two stages.
    • Stage 1: 13 Nm
    • Stage 2: 45 degrees

  1. Rotate the crankshaft clockwise two revolutions.

  1. Check the camshaft timing by inserting the 6 mm drill bits through the holes in the camshaft sprockets and fuel injection pump sprocket.
Vehicles without common rail fuel injection
  1. Check the timing by inserting the special tool in the CKP sensor hole.
Vehicles with common rail fuel injection
  1. Check the timing by inserting the special tool in the CKP sensor hole.
All vehicles
  1. Remove the special tool from the CKP sensor hole.
  1. Remove the drill bits from the holes in the camshaft sprockets and fuel injection pump sprocket.
  1. Install the CKP sensor.
    For additional information, refer to: Crankshaft Position (CKP) Sensor - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (303-14 Electronic Engine Controls, Removal and Installation).
  1. Install the engine front cover. For additional information, refer to: (303-01A Engine - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel)
    Engine Front Cover - 75 PS (In-vehicle Repair),
    Engine Front Cover - 90 PS/120 PS (In-vehicle Repair).
  1. Install the valve cover. For additional information, refer to: (303-01A Engine - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel)
    Valve Cover - 75 PS/90 PS (In-vehicle Repair),
    Valve Cover - 120 PS (In-vehicle Repair),
    Valve Cover - 135 PS (In-vehicle Repair).

Exhaust Manifold > < In-vehicle Repair|Valves