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Transit 2006.5 (04.2006-)

Engine - 2.2L Duratorq-TDCi (Puma) Diesel - Camshafts Transit 2006.5 (04/2006-)
In-vehicle Repair

Special Tool(s)

Remover, O-Ring Seal

100-010 (17-063)

Timing Tool, Crankshaft

303-698 (21-251)
General Equipment
Two 6 mm drill bits
Materials
Name
Specification
Loctite 510
WSK-M2G348-A7 

Removal

WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
  1. Remove the valve cover.
    For additional information, refer to: Valve Cover (303-01 Engine - 2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
  1. Remove the engine front cover.
    For additional information, refer to: Engine Front Cover (303-01 Engine - 2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
  1. Remove the fuel pump.
    For additional information, refer to: Fuel Pump (303-04 Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
  1. Disconnect the fuel supply lines.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
  1. Remove the crankshaft position (CKP) sensor.
    For additional information, refer to: Crankshaft Position (CKP) Sensor - 2.2L Duratorq-TDCi (Puma) Diesel (303-14 Electronic Engine Controls, Removal and Installation).
  1. Remove the brake vacuum pump.
    For additional information, refer to: Brake Vacuum Pump - 2.2L Duratorq-TDCi (Puma) Diesel (206-07 Power Brake Actuation, Removal and Installation).

  1. Remove the rocker carrier.

  1. Detension the timing chain tensioner using the special tool and a 2 mm Punch.

  1. Remove the timing chain tensioner using a 2 mm Punch.

  1. Remove the timing chain guides, 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

WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
  1. Clean the mating faces of the camshaft carrier and the cylinder head.

  1. CAUTION:
    CAUTION:Do not turn the crankshaft when the special tool is fully located into the flywheel. Failure to follow this instruction will cause damage to the CKP sensor hole.
    NOTE:
    NOTE:Only turn the crankshaft in the normal direction of rotation.
    NOTE:
    NOTE:Make sure that the special tool is fully located in the flywheel so that the engine cannot be rotated in either direction.
    Rotate the crankshaft and insert the special tool through the CKP sensor hole to detect 50 degrees before top dead center (BTDC).
  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.
    • Bolts in the sequence shown in two stages.
    • Stage 1: Bolts 1 through 22 to 23 Nm.
    • Stage 2: Bolts 23 through 25 to 10 Nm.

  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 using 6 mm drill bits.

  1. Install the timing chain guides.

  1. Install the timing chain tensioner.

  1. CAUTION:
    CAUTION:The copper links of the timing chain must align with the timing marks on the camshaft sprockets.
    Check the camshaft timing by inserting the 6 mm drill bits through the holes in the camshaft sprockets and correct if necessary.
  1. Remove the 6 mm drill bits.
  1. Remove the special tool from the crankshaft position (CKP) sensor hole.

  1. Install the rocker carrier.
    • Tighten the retaining bolts in two stages.
    • Stage 1: 10 Nm.
    • Stage 2: 30 degrees.

  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Using a suitable screwdriver, turn the engine clockwise two revolutions.

  1. CAUTION:
    CAUTION:Do not turn the crankshaft when the special tool is fully located into the flywheel. Failure to follow this instruction will cause damage to the CKP sensor hole.
    NOTE:
    NOTE:Only turn the crankshaft in the normal direction of rotation.
    NOTE:
    NOTE:Make sure that the special tool is fully located in the flywheel so that the engine cannot be rotated in either direction.
    Rotate the crankshaft and check the timing by inserting the special tool in the CKP sensor hole.

  1. CAUTION:
    CAUTION:The copper links of the timing chain must align with the timing marks on the camshaft sprockets.
    Check the camshaft timing by inserting the 6 mm drill bits through the holes in the camshaft sprockets and correct if necessary.
  1. Remove the special tool and the 6 mm drill bits.
  1. Install the brake vacuum pump.
    For additional information, refer to: Brake Vacuum Pump - 2.2L Duratorq-TDCi (Puma) Diesel (206-07 Power Brake Actuation, Removal and Installation).
  1. Install the CKP sensor.
    For additional information, refer to: Crankshaft Position (CKP) Sensor - 2.2L Duratorq-TDCi (Puma) Diesel (303-14 Electronic Engine Controls, Removal and Installation).
  1. Connect the fuel lines.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
  1. Install the fuel pump.
    For additional information, refer to: Fuel Pump (303-04 Fuel Charging and Controls - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
  1. Install the engine front cover.
    For additional information, refer to: Engine Front Cover (303-01 Engine - 2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
  1. Install the valve cover.
    For additional information, refer to: Valve Cover (303-01 Engine - 2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).

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