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Disassembly and Assembly of Subassemblies > < Engine - Vehicles With: Exhaust Gas Recirculation (EGR)

Transit 2000.5 (01.2000-05.2006)

Engine - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel - Engine Transit 2000.5 (01/2000-05/2006)
Disassembly

Special Tool(s)

Universal Flange Holding Wrench

205-072

Separator, Oil Pan

303-428 (21-179)

Mounting Stand

303-435

Mounting bracket for 303-435

303-435-06

Mounting plate for 303-435-06

303-435-011A

Remover/Installer, Crankshaft Front Oil Seal

303-679

Holding Wrench, Crankshaft

303-1177
General Equipment
Spatula
All vehicles
  1. Mount the engine on the mounting stand.
  1. Drain the engine.
    • Allow the oil to drain into a suitable container.

  1. NOTE:
    NOTE:Inspect the oil pan drain plug seal for damage. Install a new oil pan drain plug and seal if required.
    Install the drain plug.

  1. Remove the oil level indicator tube and disconnect the positive crankcase ventilation (PCV) hose from the valve cover.
Vehicles with exhaust gas recirculation (EGR)
  1. Remove the EGR cooler to EGR valve tube.

  1. NOTE:
    NOTE:Make a note of the position of the EGR cooler to exhaust manifold retaining clamp to make sure it is installed in the same position.
    Remove the EGR cooler.
    • Discard the gasket and the clamp.
All vehicles
  1. Disconnect the oil supply tube from the turbocharger.
    • Discard the sealing washers.

  1. Remove the turbocharger and exhaust manifold assembly.
    • Discard the gasket, the bolts and the nuts.

  1. Remove the exhaust manifold studs.
    • Discard the studs.
Vehicles with EGR
  1. Disconnect the EGR valve electrical connector.

  1. Disconnect the intake air temperature (IAT) sensor electrical connector.

  1. Disconnect the fuel injection pump and oil pressure switch electrical connectors.
Vehicles without EGR
  1. Disconnect the fuel injection pump vacuum line from the intake manifold tube.

  1. Disconnect the fuel shutoff solenoid and oil pressure switch electrical connectors.
All vehicles
  1. Disconnect the glow plug wire and the cylinder head temperature (CHT) sensor electrical connectors.

  1. Remove the power steering pump and generator mounting bracket.

  1. Remove the water pump.
    1. Disconnect the hoses.
    1. Remove the bolts.
    • Discard the gasket.

  1. Remove the oil cooler.
    1. Disconnect the hoses.
    1. Remove the bolts.

  1. Remove the intake manifold (nine bolts).

  1. Remove the high-pressure fuel supply lines.
    • Discard the supply lines.

  1. Remove the fuel injector return line.
    For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).
    • Discard the line and sealing washers.

  1. Disconnect the coolant outlet and degas connector from the engine.
    1. Disconnect the degas hose.
    • Discard the hose.
    1. Remove the bolts.
    • Discard the O-ring seal.

  1. Remove the thermostat housing.

  1. Remove the accessory drive belt idler pulley and the cooling fan pulley.

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

  1. Using the special tool, remove the crankshaft front oil seal.
    • Discard the seal.
Vehicles built up to 06/2000
  1. CAUTION:
    CAUTION:Vehicles built up to 06/2000 have M6 x 14 mm engine front cover bolts. These bolts must be discarded and new M6 x 16 mm bolts installed.
    Remove the engine front cover nuts and bolts.
    • 2 nuts.
    • 20 bolts.
    • Discard the bolts, if required.
Vehicles built 06/2000 onwards
  1. Remove the engine front cover nuts and bolts.
    • 2 nuts.
    • 20 bolts.
All vehicles
  1. NOTE:
    NOTE:Lubricate the spatula with clean engine oil.
    NOTE:
    NOTE:Engine front cover can be distorted during removal.
    Using the special tool and a spatula, separate the engine front cover from the engine.
    • Insert the special tool between the engine front cover and the engine, slide the special tool counterclockwise, make enough room for the spatula and return the special tool to the original position.
    • Slide the spatula counterclockwise around the engine front cover, cutting the silicone gasket.
    • Remove and discard the engine front cover.

  1. Remove the valve cover.
    • Discard the valve cover gasket and valve cover fuel injector seals.

  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 timing chain guides.

  1. Remove the fuel injection pump sprocket.

  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.

  1. NOTE:
    NOTE:The fuel injector locking sleeves must be fully released in order to remove the fuel injectors.
    Loosen the fuel injector locking sleeves and remove the fuel injectors by gently working them loose.

  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 fuel injection pump.
    • Detach the fuel injection pump bracket from the engine.
    • Discard the gasket.

  1. Remove the coolant distribution manifold.
    • Discard the gasket.

  1. Remove the oil pan retaining bolts.

  1. CAUTION:
    CAUTION:Do not distort the oil pan.
    Using a suitable spatula, remove the oil pan.
    • Slide the spatula around the profile of the oil pan.
Vehicles built up to 05/2003
  1. Remove the hydraulic oil pump chain tensioner.
    1. Detension the chain.
    1. Lock the tensioner by inserting a pin.
    1. Remove the bolts.
Vehicles built 05/2003 onwards
  1. Remove the mechanic oil pump chain tensioner.
    1. Install the retaining bolt and tension the tensioner.
    1. Lock the tensioner by inserting a pin.
    1. Remove the leaf spring from the retaining stud.
    • Remove the retaining bolt.
All vehicles
  1. Remove the oil pump pickup tube.

  1. Remove the oil pump.
    • Remove the chain from the crankshaft sprocket.
Vehicles with common rail fuel injection
  1. Remove the crankshaft position (CKP) sensor.
    • Discard the CKP sensor.
Vehicles without common rail fuel injection
  1. Remove the crankshaft position (CKP) sensor.
All vehicles
  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.
Vehicles with 75 PS, 90 PS, 115 PS, 120 PS or 125 PS diesel engine
  1. Remove the flywheel.
    • Discard the bolts.
Vehicles with 135 PS diesel engine
  1. NOTE:
    NOTE:This step is only required if the flywheel retaining bolts are not visible.
    Install the special tools.

  1. NOTE:
    NOTE:This step is only required if the flywheel retaining bolts are not visible.
    Using the special tools, rotate the primary mass of the flywheel until the retaining bolts are visible.

  1. Remove one flywheel retaining bolt.
    • Discard the bolt.

  1. Using the special tool, lock the primary and secondary mass of the flywheel.
    • Remove the special tools, 205-072 and 205-072-02.
  1. Remove the flywheel retaining bolts.
    • Discard the bolts.

  1. Remove the special tool and the remove the flywheel.
All vehicles
  1. Remove the crankshaft rear seal carrier.
    • Discard the carrier.

  1. CAUTION:
    CAUTION:Remove the ladder frame bolts in the sequence shown.
    Remove the ladder frame.
    • Discard the gasket.

  1. Remove the connecting rod bearing caps.
  1. Remove the pistons.

  1. Remove the crankshaft main bearing caps.
  1. Remove the crankshaft.

Disassembly and Assembly of Subassemblies > < Engine - Vehicles With: Exhaust Gas Recirculation (EGR)