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Exhaust Manifold > < Camshafts

Transit 2000.5 (01.2000-05.2006)

Engine - 2.3L DOHC-16V - Timing Chain Transit 2000.5 (01/2000-05/2006)
In-vehicle Repair

Special Tool(s)

Flange Holding Wrench, Universal

205-072 (15-030A)
General Equipment
2.5 mm drill bit
Brass drift
M6 x 60 mm bolt

Removal

  1. Remove the ignition coils. For additional information, refer to Section  303-07A Glow Plug System / 303-07B Glow Plug System / 303-07C Engine Ignition.

  1. Remove the spark plugs (engine shown removed for clarity).

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

  1. Remove the engine front lifting eye.

  1. Remove the valve cover.

  1. Detach the coolant hose from the cylinder head.

  1. Remove the engine upper front cover.
    • Discard the gasket.

  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Turn the engine to top dead center (TDC).

  1. Remove the timing chain upper guide.
    • Discard the guide.

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

  1. Remove the timing chain right-hand guide upper retaining bolt.
  1. Using a suitable piece of wire, secure the timing chain to the exhaust manifold to prevent it from dropping into the timing case.

  1. CAUTION:
    CAUTION:Prevent the timing chain tensioner pivot bolt retaining washer from dropping into the timing case.
    Remove the timing chain tensioner.
    1. Remove the retaining washer.
    1. Using a M6 x 60 mm bolt, remove the pivot bolt.

  1. Remove the timing chain tensioner.
    • Discard the timing chain tensioner.
  1. Remove the engine front cover.
    For additional information, refer to Engine Front Cover in this section.

  1. Detension and lock the oil pump chain tensioner.
    1. Retract the pawl.
    1. Insert a 2.5 mm drill bit.

  1. Remove the oil pump chain tensioner.

  1. Remove the oil pump chain guides.
  1. Detach the oil pump chain from the crankshaft sprocket.

  1. Remove the timing chain lower guide retaining bolt.
  1. Remove the timing chain and the timing chain lower guide.

Installation
  1. NOTE:
    NOTE:The copper link of the timing chain must align with the timing mark on the crankshaft sprocket.
    Install the timing chain and the timing chain lower guide.

  1. Tighten the timing chain lower guide retaining bolt.
  1. Lower the vehicle.

  1. CAUTION:
    CAUTION:Do not install a fully or partially released timing chain tensioner.
    Install a new timing chain tensioner.

  1. CAUTION:
    CAUTION:Prevent the timing chain tensioner pivot bolt retaining washer from dropping into the timing case.
    Install the timing chain tensioner arm.
    1. Using a M6 x 60 mm bolt, install the pivot bolt.
    1. Install the retaining washer.

  1. Install the timing chain right-hand guide upper retaining bolt.

  1. CAUTION:
    CAUTION:Make sure that the camshaft sprockets correctly locate into the slots in the camshafts.
    NOTE:
    NOTE:The copper link of the timing chain must align with the timing mark on the camshaft sprocket.
    NOTE:
    NOTE:The timing chain must be taut between the exhaust camshaft sprocket and the crankshaft sprocket.
    NOTE:
    NOTE:Do not fully tighten the camshaft sprocket retaining bolt at this stage.
    Install the exhaust camshaft sprocket and the timing chain.

  1. NOTE:
    NOTE:The copper link of the timing chain must align with the timing mark on the camshaft sprocket.
    NOTE:
    NOTE:Do not fully tighten the camshaft sprocket retaining bolt at this stage.
    Install the inlet camshaft sprocket and the timing chain.

  1. NOTE:
    NOTE:If the plunger of the timing chain tensioner does not reach the timing chain tensioner, use the special tool to release it as described in the following two steps.
    Using a suitable brass drift, release the timing chain tensioner.

  1. Using a 220 mm length of suitable 2.5 mm diameter welding rod, fabricate a special tool.

  1. Release the timing chain tensioner.
    • Press the timing chain tensioner arm down by hand to release the timing chain tensioner.

  1. Using the special tool, tighten the camshaft sprocket retaining bolts.
  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Turn the engine two revolutions.

  1. Check the valve timing.

  1. NOTE:
    NOTE:Install a new timing chain upper guide.
    Install the timing chain upper guide.

  1. NOTE:
    NOTE:Install a new engine upper front cover gasket.
    Install the engine upper front cover.
    • Use a suitable straight edge to align the top edge of the engine upper front cover with the cylinder head.

  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Turn the engine to bottom dead center (BDC).
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Check the alignment of the balance shaft gears.

  1. NOTE:
    NOTE:The copper links of the timing chain must align with the timing marks on the crankshaft sprocket and the balance shaft sprocket.
    Install the oil pump chain.

  1. Install the oil pump chain guides.

  1. Install the oil pump chain tensioner.

  1. Unlock the oil pump chain tensioner by removing the drill bit.
  1. Install the engine front cover.
    For additional information, refer to Engine Front Cover in this section.

  1. Attach the coolant hose to the cylinder head.

  1. Install the valve cover.
    • Tighten the nuts and bolts in the sequence shown in two stages.
    • Stage 1: Tighten nuts and bolts 1 through 15 to 3 Nm.
    • Stage 2: Tighten nuts and bolts 1 through 15 to 9 Nm.

  1. Install the engine front lifting eye.

  1. Connect the CMP sensor electrical connector.

  1. Install the spark plugs (engine shown removed for clarity).
  1. Install the ignition coils. For additional information, refer to Section  303-07A Glow Plug System / 303-07B Glow Plug System / 303-07C Engine Ignition.

Exhaust Manifold > < Camshafts