303-01A-2 Engine — Diesel Duratorq-Di/TDDi (Puma) 2.

4L 303-01A-1

SECTION 303-01A Engine — Diesel Duratorq-Di/TDDi

(Puma) 2.4L
VEHICLE APPLICATION: 2004.0 Transit

CONTENT PAGE
SPECS
Specs ...................................................................................................................................... 303-01A-3
Engine data - 75 HP ............................................................................................................... 303-01A-3
Engine data - 90 hp engine with exhaust gas recirculation system
cape (EGR) .......................................................................................................................... 303-01A-3
Engine data - 90 HP engine without EGR system................................................................... 303-01A-3
Engine data - 120 HP engine with EGR system...................................................................... 303-01A-3
Engine data - 120 HP engine without EGR system................................................................. 303-01A-4
Engine oil capacity - 75 and 90 HP.......................................................................................... 303-01A-4
Engine oil capacity - 120 HP.................................................................................................... 303-01A-4
Dimensions of the monoblock.................................................................................................. 303-01A-4
Piston dimensions ................................................................................................................... 303-01A-4
Crankshaft dimensions ........................................................................................................... 303-01A-5
Connecting rod dimensions..................................................................................................... 303-01A-5
Piston pin dimensions ............................................................................................................. 303-01A-5
Camshaft dimensions.............................................................................................................. 303-01A-5
Valve dimensions .................................................................................................................... 303-01A-5
Cylinder head dimensions ...................................................................................................... 303-01A-5
Oil pressure specifications....................................................................................................... 303-01A-6
DESCRIPTION AND OPERATION
Engine ..................................................................................................................................... 303-01A-9
Overview ................................................................................................................................. 303-01A-9
Engine Identification Code..................................................................................................... 303-01A-10
Engine identification plate...................................................................................................... 303-01A-10
General information ............................................................................................................... 303-01A-10
Cylinder head......................................................................................................................... 303-01A-11
Rocker arrows........................................................................................................................ 303-01A-12
Camshafts and camshaft carrier ........................................................................................... 303-01A-13
Camshaft carrier .................................................................................................................... 303-01A-15
Cylinder head and valves ...................................................................................................... 303-01A-15
Camshaft drive....................................................................................................................... 303-01A-16
Monoblock and crankcase - General view ............................................................................ 303-01A-16
Cranks.................................................................................................................................... 303-01A-18
Pistons.................................................................................................................................... 303-01A-18
Crankshaft.............................................................................................................................. 303-01A-20
Monoblock.............................................................................................................................. 303-01A-21
Oil splash nozzles ................................................................................................................. 303-01A-21
DIAGNOSIS AND CHECKS
Engine ................................................................................................................................... 303-01A-22
VEHICLE REPAIRS
Intake manifold ..............................................................................................(21 183 0) 303-01A-23
Aiming cap — 120 PS ................................................................................... (21 141 0) 303-01A-27

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Front crankshaft seal.......................................................................................(21 467 0) 303-01A-36

Front engine cover — 90 PS/120 PS..............................................................(21 148 0) 303-01A-38
Valve springs.......................................................................................................................... 303-01A-44
Valve seals......................................................................................................(21 238 0) 303-01A-46
Valves..............................................................................................................(21 215 4) 303-01A-47
Camshafts.......................................................................................................(21 284 0) 303-01A-48
Exhaust manifold.............................................................................................(21 187 0) 303-01A-55
Cylinder head..................................................................................................(21 163 0) 303-01A-59
Oil pan.............................................................................................................(21 154 0) 303-01A-65
Oil pump..........................................................................................................(21 714 0) 303-01A-68
Rear crankshaft seal ..................................................................................... (21 468 4) 303-01A-70
DISASSEMBLY AND INSTALLATION
Engine — Vehicles with Exhaust Gas Recirculation (EGR)................................................... 303-01A-72
DISASSEMBLY
Engine.............................................................................................................(21 134 8) 303-01A-82
DISASSEMBLY AND ASSEMBLY OF SUB-COMPONENTS
Cylinder head.................................................................................................(21 165 6) 303-01A-94
MOUNTING
Engine............................................................................................................(21 134 8) 303-01A-96
FACILITY
Engine — Vehicles with Exhaust Gas Recirculation (EGR)................................................. 303-01A-124

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SPECS

Engine data - 75 HP
Description
Code F4FA
Firing order 1-3-4-2
Cylinder diameter 89.9 mm
Career 94.6 mm
Displacement 2,402 cc
Compression ratio 19:1
Power output at 3,500 rpm 55 kW (75 hp)
Engine torque at 2,000 rpm 185 Nm
Minimum walking speed 900 rpm
Maximum permissible engine speed - continuous 4,900 rpm
Maximum allowable engine speed - intermittent 4,900 rpm

Engine data - 90 hp engine with exhaust gas recirculation (EGR) system

Description
Code D2FA
Firing order 1-3-4-2
Cylinder diameter 89.9 mm
Career 94.6 mm
Displacement 2,402 cc
Compression ratio 19:1
Power output at 4,000 rpm 66 kW (90 hp)
Engine torque at 1,800 rpm 200 Nm
Minimum walking speed 900 rpm
Maximum permissible engine speed - continuous 4,900 rpm
Maximum allowable engine speed - intermittent 4,900 rpm

Engine data - 90 HP engine without EGR system

Description
Code HEFA
Firing order 1-3-4-2
Cylinder diameter 89.9 mm
Career 94.6 mm
Displacement 2,402 cc
Compression ratio 19:1
Power output at 4,000 rpm 66 kW (90 hp)
Engine torque at 1,600 rpm 210 Nm
Minimum walking speed 800 rpm
Maximum permissible engine speed - continuous 4,600 rpm
Maximum allowable engine speed - intermittent 4,600 rpm

Engine data - 120 HP engine with EGR system

Description
Code D4FA
Firing order 1-3-4-2
Cylinder diameter 89.9 mm
Career 94.6 mm
Displacement 2,402 cc
Compression ratio 19:1

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SPECIFICATIONS (CONTINUED)

Description
Power output at 4,000 rpm 88 kW (120 hp)
Engine torque at 2,300 rpm 240 Nm
Minimum walking speed 900 rpm
Maximum permissible engine speed - continuous 4,900 rpm
Maximum allowable engine speed - intermittent 4,900 rpm

Engine data - 120 HP engine without EGR system

Description
Code HFFA
Firing order 1-3-4-2
Cylinder diameter 89.9 mm
Career 94.6 mm
Displacement 2,402 cc
Compression ratio 19:1
Power output at 4,000 rpm 88 kW (120 hp)
Engine torque at 1,800 rpm 245 Nm
Minimum walking speed 800 rpm
Maximum permissible engine speed - continuous 4,600 rpm
Maximum allowable engine speed - intermittent 4,600 rpm

Engine oil capacity - 75 and 90 HP

Description Liters
Initial fill, including oil filter 7,22
Service filling, including oil filter 7,00

Engine oil capacity - 120 HP

Description Liters
Initial fill, including oil filter 7,22
Service filling, including oil filter 6,50

Dimensions of the monoblock

Description mm

Cylinder bore, class 1 89,900-89,910

Cylinder bore, class 2 89,910-89,920
Cylinder bore, class 3 89,920-89,930
Main bearing shell diameter 1 to 4 - bearings installed 65,003-65,030

Main bearing shell diameter 5 - bearing installed 70,004-70,033

Radial clearance of main bearings 1 to 4 0,005-0,051
Main bearing radial clearance 5 0,004-0,054
Main bearing housing diameter 1 to 4 - vertical measurement 69,504-64,520

Main bearing housing diameter 5 - vertical measurement 74,504-74,520

69,502-69,525
Main bearing housing diameter 1 to 4 - horizontal measurement
Main bearing housing diameter 5 - horizontal measurement 74,502-74,525

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SPECIFICATIONS (CONTINUED)

Piston dimensions
Description mm

Piston diameter, class 1 89,84-89,85

Piston diameter, class 2 89,85-89,86
Piston diameter, class 3 89,86-89,87
0,05-0,07

Piston to cylinder clearance Ring end clearances - upper compression 0,25-0,50

ring - lower compression ring 0,50-0,75
- oil control ring 0,25-0,50
Ring clearance position: Ring end clearances should be evenly distributed around the circumference of the piston.
The elements of the oil control ring must be arranged in the same way. Align the end gaps of the rings at 120
degrees to each other.

Crankshaft dimensions
Description mm

Floating the end of the main bearing journal 0,090-0,305

Diameter of main bearing journals 1 to 4 64,950-64,970
Diameter of main bearing journal 5 69,950-69,970
Connecting rod bearing journal diameter 52,980-53,000

Connecting rod dimensions

Description mm

Big End Housing Diameter 55,096-56,015

Small End Housing Diameter 30,010-30,018
Connecting rod bearing shell inner diameter - bearings installed 53,017-53,043
Connecting rod bearing radial clearance 0,034-0,100
Connecting rod bearing axial clearance 0,100-0,320

Piston pin dimensions

Description mm

Piston pin length 65,850-66,150

Piston pin diameter 32,000-31,996
Piston pin sliding clearance 0,002-0,012

Camshaft dimensions
Description mm
Camshaft axial clearance 0,125
Diameter of camshaft bearing journals 26,450
Camshaft bearing clearance - radial measurement 0,065

Valve dimensions
Description mm

0,045
Valve stem to valve guide clearance - intake valve
0,055
Valve stem to valve guide clearance - exhaust valve

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SPECIFICATIONS (CONTINUED)

Cylinder head dimensions

Description mm
Maximum distortion - measured transversely and diagonally 0,10
Flatness of the contact surface 0,02
Cylinder head gasket thickness with piston protruding 0.310 - 0.400 1.1 (a drill/tooth)
mm
Cylinder head gasket thickness with piston protruding 0.401 - 0.450 1.15 (two holes/teeth)
mm
Cylinder head gasket thickness with piston protruding 0.451 - 0.500 1.2 (three holes/teeth)
mm

Oil pressure specifications

Description bars
Minimum oil pressure at idle speed 1,25
Minimum oil pressure at 2,000 rpm 2,0

Tightening specifications
Description Nm lb-ft lb-in
Transmission retaining bolts 40 30 -
Engine crossmember support bracket retaining 40 30 -
screws
103 76 -
Engine support insulator retaining nuts
80 59 -
Vibration damper screw to engine crossmember
80 59 -
Driveshaft bolts to transmission output shaft flange
(vehicles built up to 10-01)
115 85 -
Driveshaft bolts to transmission output shaft flange
(vehicles built 10-01 and later)
Engine crossmember retaining screws 70 52 -
Transmission support insulator bolts to front axle 40 30 -
crossmember
15 11 -
Engine ground wire screw to side rail
12 9 -

Jumper wire retaining nut to starter solenoid

Engine wiring harness electrical connector retaining 7 - 62
screw
Radiator support retaining screws 9 - 80
Short shifter screws 12 9 -
10 - 89
Sight cover retaining screws and nuts
Thermostat housing retaining screw 22 16 -
23 17 -
Thermostat housing bracket retaining screws
Crankshaft pulley retaining bolts to - -
10 - 89
Crankshaft rear oil seal carrier retaining screw
Flywheel retaining screws to - -

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SPECIFICATIONS (CONTINUED)

Description Nm lb-ft lb-in

to - -
Crankshaft main bearing cap retaining screws
Connecting rod bearing cap retaining screws to - -
Injectors 52 38 -
22 16 -
Fuel injection pump retaining screws
32 24 -
Fuel injection pump gear retaining screws
35 26 -
High pressure fuel supply line connections
(vehicles with exhaust gas recirculation (EGR))
High pressure fuel supply line connections 25 18 -
(vehicles without EGR)
Injector return pipe unions 8 - 71
Ladder type chassis retaining screws to - -
to - -
Camshaft carrier retaining bolts
Rocker arm shaft retaining screws to - -
15 11 -
Timing chain guide retaining bolts
15 11 -
Timing chain tensioner retaining bolts
16 12 -
Oil pump chain tensioner retaining bolts
33 24 -
Camshaft gear retaining screws
Accessory drive belt tensioner bracket retaining 22 16 -
screws
Alternator retaining bolts 48 35 -
Alternator bracket retaining bolts 22 16 -
EGR valve retaining screw 10 - 89
20 15 -
Exhaust manifold to EGR valve tube retaining bolts
10 - 89
Intake manifold tube retaining screws
18 13 -
Fuel injection pump vacuum pipe union
Water pump retaining screws 23 17 -
Screw the coolant outlet and the gas connector to 22 16 -
the engine
Drain panel retaining screws 12 9 -
12 9 -
Windshield wiper motor bracket retaining screws
22 16 -
Wiper arm retaining nuts
22 16 -
Oil dipstick tube retaining screws
10 - 89
Oil pump pickup tube retaining screws
Oil cooler retaining bolts 23 17 -
Oil pump retaining screws to - -
Oil pan drain plug 23 17 -

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SPECIFICATIONS (CONTINUED)

Description Nm lb-ft lb-in

Oil pan retaining bolts to - -
10 - 89
Coolant distribution manifold retaining screws
23 17 -
EGR cooler bolts to cylinder head.
Cylinder head bolts to - -
14 11 -
Front engine cover retaining screws
10 - 89
Front engine cover retaining nuts
53 39 -
Accessory drive belt idler pulley retaining screws
53 39 -
Cooling fan pulley retaining screws
Glow plugs 12 9 -
23 17 -
Power steering pump retaining bolts
22 16 -
Power steering pump bracket retaining bolts
Intake manifold retaining bolts 15 11 -
Exhaust manifold retaining screws 40 30 -
Exhaust manifold studs 20 15 -
10 - 89
Turbocharger oil return line retaining screws
9 - 80
Turbocharger oil feed pipe union
23 17 -
Front engine lifting eye retaining screw
7 - 62
Crankshaft position (CKP) sensor retaining screw
Cylinder head temperature (CHT) sensor retaining 10 - 89
screw
Wiring harness retaining screw 5 - 44
50 37 -
Front undercarriage protection bar retaining bolts
(4.25 tonne single cab chassis)
a) Refer to the procedure in this section.

Lubricants, fluids, sealants and adhesives

Element Specification
Ford Formula E SAE 5W-30 engine oil (vehicles with exhaust gas WSS-M2C913-A
recirculation (EGR) system)
SAE 10W-30 engine oil (vehicles without EGR system) WSS-M2C921-A
Sealant - Oil pan, camshaft carrier and front engine cover WSE-M4G323-A4

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DESCRIPTION AND OPERATION

Engine
Overview

Ref. Description
Ref. Description
Part No.
Part No. 5 -
1 - Intake manifold Water-cooled exhaust gas -
2 - Aiming cap recirculation (EGR) system
cooler (if equipped)
3 - Camshaft carrier
6 - Oil cooler/oil filter
4 - Cylinder head

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DESCRIPTION AND OPERATION (CONTINUED)

Ref. Description Ref. Description

Part No. Part No.
Reinforcement intermediate
7 - 2 - Vehicle Identification Number
crankcase
8 - Oil pan 3 - Engine code
9 -
Fully electronic fuel injection
pump Engine identification plate
10 -
EGR connector (if equipped)
11 -
EGR valve (if equipped)

Engine Identification Code

Engine code and engine serial number
On the 2.4L engine, the engine code (4 digits)
and engine serial number (2 letters for the year
and month and 5 digits for the serial number) are
stamped on the exhaust side of the block (next to
cylinder No. 4).
Engine codes are assigned to engines as follows: The engine identification plate is located on the
timing cover cover.
• 55 kW/75 HP = F4FA
Contains the following data:
• 66 kW/90 HP = D2FA
• 88 kW/120 HP = D4FA • date and time of manufacture
• engine part number
If the engine or monoblock is replaced, the
vehicle identification number must be stamped in
the indicated place.
General information
The 2.4L turbocharged engine employs the direct
injection principle.
It is a 4-cylinder turbocharged diesel engine with
two overhead camshafts and 16 valves.
This engine is available with different power
levels:
• 55 kW/75 HP (without intercooling)
• 66 kW/90 hp (with intercooling)
• 88 kW/120 hp (with intercooling)
The valves are actuated by rocker arms, which
are in turn actuated by two camshafts in the
cylinder head.
The camshafts and fuel injection pump are
driven from the crankshaft by a double timing
chain.
Ref. Description An EEC V engine control module (PCM) is used
for engine control. The diagnosis
Part No.
1 - Engine serial number

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DESCRIPTION
DESCRIPTION AND AND OPERATION
OPERATION (CONTINUED)
(CONTINUED)

It is done with the FDS 2000 or the WDS through the Cylinder Head Data Link Connector (DLC).
Ref. Description Ref. Description
The two injection pumps operate on the "pilot injection" principle, which results in a reduction in engine
noise level.
Part No. Part No.
3 -
Rocker arm shaft with rocker 8 - Cylinder head gasket
arms (intake)
4 - Camshaft carrier The sight cover incorporates the crankcase
ventilation valve.
5 - Exhaust camshaft
6 - Intake camshaft
Rocker arrows
7 - Cylinder head

Ref. Description 2 -
Rocker arm arrow with rocker
Part No. arms (exhaust)
1 - Aiming cap
Ref. Description
Part No.

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DESCRIPTION AND OPERATION (CONTINUED)

Ref. Description
Part No.
1 -
Exhaust valve rocker arm
arrow
2 -
Exhaust valve rocker arms

3 -
Oil feed auger

4 -
Intake valve rocker arm arrow

5 - Intake valve rocker arms

6 - Helical spring

7 -
Timing chain connecting links
8 - Timing marks
Rocker arm arrow
9 -
identification

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DESCRIPTION AND OPERATION (CONTINUED)

Camshafts and camshaft carrier

Ref. Description
Ref. Description
Part No.
Part No. 5 - Sealant cord
1 - Exhaust camshaft
to - Separation between cams
2 - Intake camshaft
The intake and exhaust camshafts are
3 - Camshaft carrier differentiated by the spacing between the cams;
4 - Bearing caps see illustration ("a").

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DESCRIPTION AND OPERATION (CONTINUED)
Camshaft carrier of the same and the upper face of the cylinder
The camshafts are held in place at the top by a head.
carrier incorporating five bearing caps.
The camshaft carrier is bolted flush to the cylinder Cylinder head and valves
head and holds the camshafts.
The cylinder head is made of aluminum and
The shape of the camshaft carrier prevents it from cannot be ground.
being mounted incorrectly.
Before mounting the carrier, the contact surfaces There are four valves per cylinder, which allows
on the underside must be thoroughly cleaned. for better cylinder filling, a compact combustion
chamber and a vertical fuel injector, which
ensures optimal fuel distribution in the
combustion chamber.

Ref. Description
Ref. Description
Part No.
Part No. 5 - Valve collar
1 - Cylinder head
6 - Spring retainer
2 - Outer cylinder head bolt 7 - Spring

3 - 8 -
Cylinder head inner screw Valve stem oil seal
4 - Intake valves 9 - Exhaust valve
10 - Intake valve

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DESCRIPTION AND OPERATION (CONTINUED)

Ref. Description Ref. Description

Part No. Part No.
11 - Valve stem Reinforcement intermediate
C -
crankcase
12 - Cylinder head gasket 1 -

13 - Exhaust valves Exhaust camshaft gear

2 - Timing chain guide

Camshaft drive
3 - Intake camshaft gear
The crankshaft gear drives the camshafts and
fuel injection pump via the double timing chain in
the direction indicated by the arrow. 4 - Timing chain guide
When installing the timing chain, the marked links 5 -
must be aligned with the timing marks on the
camshaft and injection pump gears. Fuel injection pump gear

6 - Timing chain guide

7 - Crankshaft gear

8 - Timing chain tensioner

9 - Timing chain tensioner arm

TIE0031815

Ref. Description
Part No.
TO - Cylinder head
B - Monoblock

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DESCRIPTION AND OPERATION

Monoblock and crankcase -

General view

Ref. Description
Ref. Description
Part No.
Part No. 3 - Monoblock
1 - Oil pan
4 - Lower bearing shell
Reinforcement intermediate
2 - 5 - Bearing cap
crankcase
6 - Crankshaft

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DESCRIPTION AND OPERATION (CONTINUED)

Ref. Description Connecting rod and bearing cap are

marked with the corresponding length code
Part No. (H to J).
7 - Upper bearing shell • H = 149.74 mm
• I = 149.80 mm
• J = 149.86 mm
Crank
Only connecting rods of the same length
s
Cranks are available in three different lengths. should be installed.
For identification, the large end of the

Ref. Description
Pistons
Part No.
1 - Ring To ensure optimum cylinder sealing, when
installing the piston rings be sure to space the
2 - Piston pin ring clearances 120 degrees apart.
3 - Connecting rod The areas of the piston skirt that come into
contact with the cylinder have molybdenum-
4 - Big end of connecting rod coated surfaces. This counteracts the
5 - Projection appearance of scratches on the cylinder and
piston and therefore increases the service life of
6 - Bearing cap the engine.
7 - Retaining screws Make sure to install the pistons in the correct
8 - Length Identification position. The arrow on the big end of the piston

9 - Bearing shell

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DESCRIPTION AND OPERATION (CONTINUED)
and the skirt mark should point towards the The installed piston size (skirt diameter code)
front of the engine. must correspond to the cylinder diameter code.

Ref. Description
Ref. Description
Part No.
Part No.
TO - C -
Upper compression ring Oil control ring groove
groove D -
B -
Lower compression ring Piston without oil cooling holes
groove (75/90 hp)

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DESCRIPTION AND OPERATION (CONTINUED)

Ref. Description Ref. Description

Part No. Part No.
AN -
D 7 - Skirt diameter code
Piston with oil cooling holes
(120 hp)

1 - Upper compression ring Crankshaft

The crankshaft has induction hardened journals
2 - Lower compression ring
running within five bearings with clamped two-
3 - Oil control ring layer bearing shells.
Bearing caps are numbered (cylinder nos. 2, 3,
4 - Molybdenum coated surfaces and 4) or marked with the letters "F" (front) or "R"
(rear) and have an arrow that should point
5 - Piston skirt mark toward the front of the engine.
6 - Engine cooling code

Ref. Description
Ref. Description
Part No.
Part No. Upper bearing shell No. 3 with
1 - Crankshaft 3 -
flange
2 - Upper bearing shell 4 - Bearing cap
5 - Lower bearing shell

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DESCRIPTION AND OPERATION (CONTINUED)

Monoblock
The cylinders are machined directly on the
monoblock.
Three different cylinder diameters are used in
production to ensure extremely precise
adjustment of the clearance between the pistons
and cylinders.
Once the cylinder diameter is established, the
appropriate piston is installed. Three piston sizes
are also available in production.

Ref. Description
Ref. Description
Part No.
1 - Monoblock Part No.
2 - 1 - Oil splash nozzle
Location of fuel injection pump
3 - Timing box

Oil splash nozzles

The oil splash nozzles for cooling the pistons are installed under the cylinders, between the crankshaft
bearings.

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DIAGNOSIS AND CHECKS

Engine

SEE section 303-00.

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VEHICLE REPAIRS

Intake manifold (21 183 0)

Disassembly 5. Remove the hood gasket.

All vehicles
1. Disconnect the battery ground cable. For
more information, see section 414-01.
2. NOTE: Make sure the wiper motor is in the
rest position.
Remove the wiper arms.

6. NOTE: The windshield washer hose passes

through the cowl panel.
Remove the shell panel.
1. Remove the lower retaining screws.
2. Detach the windshield washer hose.
3. Separate the clasps.

3. Remove the upper retaining screws from

the body panel.
• Remove the screw covers.

4. Lift the chest.

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VEHICLE REPAIRS (CONTINUED)

7. Remove the drain tube retaining clips. 10. Remove the drain panel.

8. Remove the lower retaining screws from

the A-pillar outer trim panel.

9. Remove the retaining screw from the

wiper motor bracket.

13. Disconnect the fuel injection pump

vacuum line from the intake manifold
tube.

Vehicles with exhaust gas recirculation (EGR) system

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11. Remove the EGR valve. For more information, see section 303-08.
Vehicles without EGR
12. Disconnect the charge air cooler outlet tube from the intake manifold tube.

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VEHICLE REPAIRS (CONTINUED)
14. Remove the intake manifold pipe. Facility
• Discard the "O" ring seal.
All vehicles
All vehicles
1. NOTE: Install a new intake manifold
gasket.

For installation, follow the disassembly

procedure in reverse order.

15. Remove the intake manifold (engine

shown removed for clarity).
• Discard the Vehicles without
gasket. NOTE: EGR
Install a new O-ring seal from the
charge air cooler outlet tube to the intake
manifold tube.

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VEHICLE REPAIRS (CONTINUED)

All vehicles

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VEHICLE REPAIRS

Aiming cap — 120 PS (21 141 0)

2. Disconnect the cylinder head

temperature (CHT) sensor electrical
Special tools connector.
Crankshaft TDC Timing Tool
303-675 (21-234)

303675

Cu
Disassembly
Fuel Injector Seal Installation
Tool Cap 303-695 (21-248)

AN WARNING: Do not smoke or carry lit

cigarettes or open flames of any kind
when working on or near fuel system
related components. There are always
highly flammable mixtures that can
ignite. Failure to follow these warnings
may result in injury.
/ 2.. ... .

2: ATTENTION: The Diesel fuel injection

equipment is manufactured with very
precise tolerances and clearances. It is
therefore essential to maintain absolute
cleanliness when working with these
components. Always install blanking 4. Remove the intake manifold. For more
plugs on all pipes or open holes. information, see the Intake Manifold
1. Disconnect the exhaust gas recirculation procedure included in this section.
(EGR) valve. For more information, see
section 303-08.
3. Remove the engine oil filler pipe.

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VEHICLE REPAIRS (CONTINUED)

5. Disconnect the high pressure fuel feed 8. Remove the high pressure fuel supply
lines from the fuel injectors. lines.
• Discard the fuel feed lines.

6. Disconnect the high pressure fuel supply

lines from the fuel injection pump. 9. Disconnect the return line from the fuel
injectors. For more information, see
section 310-00.

7. Remove the high pressure fuel supply pipe

support bracket. 10. Remove the
fuel return line from the injectors.
• Discard the return pipe and sealing
washers.

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VEHICLE REPAIRS (CONTINUED)

11. Disconnect the positive crankcase 1. NOTE: Install a new sight cover
ventilation (PCV) hose from the bore gasket.
cover. Install the aiming cap.

12. Remove the sight cover. 2. NOTE: Install new fuel injector cap seals.
• Discard the gasket and seals.
Install the fuel injector seals to the target
cover using the special tool.

Facility
A WARNING: Do not smoke or carry lit
cigarettes or open flames of any kind 3. Connect the PCV hose to the end cap.
when working on or near fuel system
related components. There are always
highly flammable mixtures that can
ignite. Failure to follow these warnings
may result in injury.
ATTENTION: The Diesel fuel injection
equipment is manufactured with very
precise tolerances and clearances. It is
therefore essential to maintain absolute
cleanliness when working with these
components. Always install blanking
plugs on all pipes or fittings.

open holes.

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VEHICLE REPAIRS (CONTINUED)

4. NOTE: Install a new fuel injector return line. 7. NOTE: Do not tighten the high pressure fuel
supply line unions in this step.
Install the fuel return line to the injectors.
Connect the high pressure fuel supply
lines to the fuel injection pump.

5. Connect the injector tubing to the

injectors.
8. NOTE: Do not tighten the high pressure fuel
supply line unions in this step.

Connect the high pressure fuel supply

lines to the fuel injectors.

6. NOTE: Install new high pressure fuel feed

lines.
Install the high pressure fuel supply lines.

9. NOTE: The starter motor must be removed

to allow proper torque to be applied to the high
pressure fuel feed line fittings at the fuel
injection pump.
Remove the starter motor. For more
information, see section 303-06.

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VEHICLE REPAIRS (CONTINUED)

10. Tighten the high pressure fuel supply line 14. Connect the CHT sensor electrical
connections to the fuel injection pump. connector.

15. Install the EGR valve. For more

information, see section 303-08.
11. Install the starter motor. For more 16. Remove the crankshaft position (CKP)
information, see section 303-06. sensor. For more information, see section
12. Install the intake manifold. For more 303-14.
information, see the Intake Manifold 17. A CAUTION: Do not turn the engine when
procedure included in this section. the special tool is located completely
13. Install the engine oil fill tube. inside the flywheel. Failure to follow
this warning may result in damage to
the CKP sensor bore.
NOTE: Rotate the engine only in the normal
engine rotation direction.
Rotate the engine to 50 degrees before
top dead center (TDC) and insert the
special tool through the CKP sensor hole.

18. Using a suitable paint, mark the position

of the crankshaft pulley relative to the
front engine cover.

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VEHICLE REPAIRS (CONTINUED)

19. Remove the special tool from the CKP 22. Make and install a bleed tube as shown,
sensor bore. using clear plastic tubing and suitable
connectors.
1.Connect the bleed tube to the return line
from the fuel injection pump.

2.Connect the bleed tube to the fuel filter.

3.Place the bleed tube in a suitable
container.

20. Install the CKP sensor. For more

information, see section 303-14.
21. Disconnect the fuel return line from the
fuel injection pump to the fuel filter from
the fuel filter. For more information, see
section 310-00.

23. Disconnect the electrical connector

from the fuel feed pump.
24. Using a 15A fused jumper wire, supply
battery voltage and a good ground to the
fuel pump electrical connector to
activate the fuel pump.

25. Once air-free fuel comes out into

the container, remove the bleed tube.

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VEHICLE REPAIRS
VEHICLE (CONTINUED)
REPAIRS (CONTINUED)
26. Install a clear plastic tube as shown. 29. NOTE: Only one of the high pressure fuel
1. Connect the clear plastic tube to the fuel supply lines will show signs of fuel leaks.
32. NOTE: Make sure the two halves of the high
injection pump return line. Visually inspect the high pressure fuel
pressure fuel line support bracket are loosened
2. Connect the clear plastic tube to the fuel supply lines and tighten the pipe joint that
just enough to slide together. 34. Tighten the nuts
filter.
NOTE: Do not tighten the nuts on the support shows signssecuring the support
of fuel leaks.
bracket to the high pressure fuel supply
bracket to the high pressure fuel supply lines yet. lines.
Install the support bracket to the high
pressure fuel supply lines.

45,38:8

Ak
27. Make sure the engine is still at TDC by
checking the paint marks.
28. Using a 15A fused jumper wire, supply
battery- 1voltage
VUE0022932 \\ 1
and
IIk a goodP ground to the -
fuel pump electrical connector to activate
for the
133^1
em2K2
VUE0022934 I-IW 1

pressure
slowly rotate
the cylinder
9 Nm

1 II 1 V M
30. NOTE: Rotate the engine only in the normal
engine rotation direction.
35. Tighten the bolt on the support bracket
Using
highthe paint mark as a reference,
fuel supply lines to
head. the motor 180 degrees.
31. Repeat steps 29 and 30 to bleed the other
the fuel pump.
three high pressure fuel supply lines.
33. NOTE: Do not tighten the bolt securing the high
pressure fuel supply lines to the cylinder head
yet.
Install the bolt securing the high pressure
fuel supply lines to the cylinder head.

ee9/<2
VUE0022935 I-IW 1 1 II 1 V M

36. Tighten the two halves of the high

pressure fuel supply pipe support
Wete
VUE0022933 I- 1 \\ 1 1 II 1 V M bracket.

{gsBnm, 5
<2
VUE0022936 K-IW 1 IITV

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VEHICLE REPAIRS (CONTINUED)

37. Remove the jumper wire and connect the fuel lift pump electrical connector.
38. Start the engine and gently increase its speed to 1,000 rpm for approximately 2 to 3
minutes, until no air is visible in the clear plastic tube.
39. Turn off the engine.
40. Remove the clear plastic tube.
41. Connect the fuel return line from the fuel injection pump to the fuel filter to the fuel
filter.

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VEHICLE REPAIRS

Front crankshaft seal (21 467 0)

4. Using the special tool, remove

Special tools
the front oil seal from the crankshaft.
Universal flange clamping
• Discard the seal.
wrench
205-072 (15-030A)
GSa
(and 15030A
Crankshaft Front Oil Seal

/6 Removal/Installation Tool 303-

679 (21-238)

303-679

Disassembly Facility
1. Remove the accessory drive belt. For more 1. NOTE: Install a new crankshaft front oil seal.
information, see section 303-05. NOTE: A new crankshaft front oil seal is supplied
with an alignment sleeve that will be forced out
during installation.
2. Raise and support the vehicle. For more
information, see section 100-02.
3. Remove the crankshaft pulley using the
special tool.
Using the special tool, install the
crankshaft front oil seal.

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VEHICLE REPAIRS (CONTINUED)

2. /:CAUTION: The crankshaft pulley retaining screws should only be used three times.
NOTE: Mark the heads of the retaining screws with a punch according to the number of times
they have been used.
Install the crankshaft pulley using the special tool.
• Tighten the screws in two stages:
• 1st stage: 30 Nm
• 2nd stage: 95 degrees

3. Lower the vehicle.

4. Install the accessory drive belt. For more information, see section 303-05.

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VEHICLE REPAIRS

Front engine cover — 90 PS/120 PS (21 148 0)

All vehicles
4. Separate the water pump and brake
Special tools vacuum pump from the engine and set
Universal flange clamping them aside (four screws).
wrench • Discard the gasket.
205-072 (15-030A)
GSa
(and 15030A

Crankshaft front oil seal

removal/installation tool
/oo 303-679 (21-238)

•either 303-679

Front Cover Centering Tool

303-682 (21-241)

5. Separate the thermostat housing support

bracket from the cylinder head and
disconnect the upper radiator hose from
the thermostat housing.
303-682

Workshop equipment
Two spatulas
Two M10 x 60 mm guide
studs

Denomination Specification
Loctite 7070
Sealer WSE-M4G323-A4

Disassembly
All vehicles
1. Drain the cooling system. For more information, refer to section 303-03.
Vehicles without air conditioning
2. Remove the fan shroud. For more information, see section 303-03.
Vehicles with air conditioning
3. Remove the hopper and cooling fan motor. For more information, see section 303-03.

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VEHICLE REPAIRS (CONTINUED)

6. Disconnect the gas connector and the 9. Using the special tool, remove
engine coolant outlet. the front oil seal from the crankshaft.
1.Disconnect the gas hose. • Discard the seal.
• Discard the hose.
2.Remove the screws.
• Discard the "O" ring seal.

Vehicles manufactured until 06-2000

10. ATTENTION: On vehicles manufactured
up to 6-00 the front engine cover
screws are M6 x 14 mm type. These
7. Remove the accessory drive belt idler screws should be discarded and M6 x
pulley and cooling fan pulley. 16mm screws should be installed.
Remove the nuts and bolts from the front
engine cover.
• 2 nuts
• 20 screws
• Discard screws if necessary.

8. Remove the crankshaft pulley using the

special tool.

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VEHICLE REPAIRS (CONTINUED)

Vehicles manufactured from 06-2000 Facility

11. Remove the nuts and bolts from the
front engine cover. All vehicles
• 2 nuts 1. Clean the mating surfaces of the engine
• 20 screws and front cover with Loctite 7070.
2. Install two M10 x 60mm guide studs into
the monoblock to facilitate installation of
the front engine cover gaskets.
3. Install a new front engine cover gasket.

All vehicles
12. ATTENTION: Be careful not to deform the
front engine cover.
CAUTION: Lubricate the spatulas with
engine oil several times during the
separating operation.
Remove the front engine cover using two 4. ZNAUTATION: Install the front engine
suitable spatulas. cover within five minutes after
• Use a spatula to facilitate the introduction applying the sealant.
of the second one. Slide the second Apply a 3mm diameter bead of sealant to
spatula to the left around the entire profile the front engine cover.
of the front engine cover.
• Discard the gasket.

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VEHICLE REPAIRS (CONTINUED)
5. Install the front engine cover using Vehicles manufactured from 06-2000
the special tool. 8. Install the front engine cover nuts and
bolts.
• 2 nuts
• 20 screws

6. Remove the guide pins.

Vehicles manufactured until 06-2000
7. ATTENTION: Install new M6 x 16 mm front
engine cover bolts if necessary. All vehicles
Install the front engine cover nuts and 9. NOTE: Install a new crankshaft front oil seal.
bolts. NOTE: The crankshaft front oil seal is provided
• 2 nuts with an alignment sleeve that is removed during
installation.

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VEHICLE REPAIRS (CONTINUED)

10. Install the accessory drive belt idler 12. NOTE: Install a new coolant outlet
pulley and cooling fan pulley. connector "O" ring seal and a new gas hose.
Connect the gas connector and the
coolant outlet to the engine.
1.Install the screws.
2.Connect the hose.

11. Attach the thermostat housing support

bracket to the cylinder head and
connect the upper radiator hose to the
thermostat housing.

13. NOTE: Install a new water pump gasket.

Attach the water pump and brake vacuum
pump to the engine (four screws).

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VEHICLE REPAIRS (CONTINUED)

14. /! ATTENTION: The retaining screws

crankshaft pulley should be used three times at most.
NOTE: Mark the screw heads with a center punch according to the number of times they have
been used.
Install the crankshaft pulley using the special tool.
• Tighten the screws in two stages:
• 1st stage: 30 Nm
• 2nd stage: 95 degrees

Vehicles without air conditioning

15. Install the cooling fan shroud. For more information, see section 303-03.
Vehicles with air conditioning
16. Install the cooling fan motor and housing. For more information, see section 303-03.
All vehicles
17. Fill and bleed the cooling system. For more information, refer to section 303-03.

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VEHICLE REPAIRS

Valve springs

3. Loosen the valve collars.

Special tools
• Place a socket on the valve spring seat and
Valve spring compressor
tap it gently with a hammer.
303-060 (21-024)

Uo
5 21024

Adapter for 303-060 303-060-

05 (21-024-05)

_8 “F 2102405

Adapter for 303-060 303-060-

07 (21-024-07)

4. Place the corresponding piston at top dead

2102407
center (TDC).
Valve stem collar assembly 5. Using the special tools, remove the valve
tool collars.
303-362 (21-156)

21156

Disassembly
1. Remove the fuel injectors. For more
information, see section 303-04A / 303-
04B / 303-04C.
2. Remove the rocker arm shafts.
• Discard the screws.
6. Remove the valve springs.

Facility
1. Install the valve springs.

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VEHICLE REPAIRS (CONTINUED)

2. Using the special tools, install the valve

collars.

3. NOTE: Install new rocker arm shaft retaining

bolts.
NOTE: The rocker arm shaft oil lubrication holes
must face downward.
Install the rocker arm arrows.
• Tighten the screws in two stages:
• 1st stage: 13 Nm
• 2nd stage: 45 degrees

4. Install the injectors. For more information,

see section 303-04A / 303-04B / 303-04C.

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VEHICLE REPAIRS

Valve seals (21 238 0)

Special tools
Valve stem seal pliers
303-508 (21-211)

Disassembly
1. Remove the valve springs. For more information, refer to the Valve Springs procedure
included in this section.
2. Remove the valve seals with the special tool.

Facility
1. Assemble the components in the reverse order of disassembly.

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VEHICLE REPAIRS

Valves (21 215 4)

3. Using the special tools, remove the valve

Special tools collars.
Valve spring compressor
303-060 (21-024)

5 21024

Adapter for 303-060 303-060-

05 (21-024-05)
=
OF 2102405

Adapter for 303-060 303-060-

07 (21-024-07)
4. Remove the valve springs.
( 2102407 5. Remove the valves.

Facility
Valve Stem Collar Installer
303-362 (21-156) 1. Install the valves.
TO 2. Install the valve springs.
21156
3. Using the special tools, install the valve
collars.

Disassemb
ly
1. Remove the cylinder head.
2. Loosen the valve collars.
• Place a socket on the valve spring seat
and tap it gently with a hammer.

4. Install the cylinder head.

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VEHICLE REPAIRS

Camshafts (21 284 0)

4. Remove the rocker arm shafts.
• Discard the screws.
Special tools
Crankshaft TDC Timing
Tool
303-675 (21-234)

303675

Workshop equipment
Three 6mm drill bits

Denomination Specification
5. Release tension on the timing chain
Loctite 7070
tensioner and lock it.
Loctite 510 WSK-M2G348-A7 1.Retract the ratchet.
2.Push the locking device inwards.
3.Insert a pin.
Disassembly
1. Remove the sight cover. For more
information, refer to the Sight Cover
procedure included in this section.
2. Remove the front engine cover. For more
information, refer to the procedure Front
Engine Cover - Vehicles with 75 PS Engine
/ Front engine cover - Vehicles with 90 PS
or 120 PS engine included in this section.
3. Remove the crankshaft position (CKP)
sensor. For more information, refer to
section 303-14.

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VEHICLE REPAIRS (CONTINUED)

6. Remove the timing chain tensioner and 9. /:CAUTION: Remove the camshaft carrier
right timing chain guide. bolts in the sequence shown.

Remove the camshaft carrier.

7. Remove the upper timing chain guide.

ELE0012982

8. Remove the gears and timing chain. 10. Remove the camshafts.

Facility
1. Clean the mating surfaces of the camshaft
carrier and cylinder
head with Loctite 7070.

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VEHICLE REPAIRS (CONTINUED)

2. Rotate the engine to 50 degrees before 5. Install the camshaft carrier.

top dead center (TDC) and insert the • Tighten the screws in the sequence
special tool through the CKP sensor hole. shown in two stages.
• 1st stage: Tighten screws 1 to 22 to 23
Nm.
• 2nd stage: Tighten screws 23 to 25 to 10
Nm.

3. Apply a 2.5 mm diameter bead of Loctite

510 to the mating surface of the cylinder
head.

6. Install the timing chain tensioner and

right timing chain guide.

4. Install the camshafts.

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VEHICLE REPAIRS (CONTINUED)

- /N , —.k.. . . . . . . 9. Install the upper timing chain guide.

7. 2: ATTENTION: The copper links of the
timing chain must coincide with the
timing marks on the camshaft gears.

Install the camshaft gears and timing

chain.

10. Loosen the fuel injection pump gear

retaining screws.

8. Insert 6mm drill bits through the camshaft

gear holes and hand tighten the gear
retaining screws.

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VEHICLE REPAIRS (CONTINUED)

11. /:ATTENTION: The copper link of the 13. Tighten the camshaft gear and fuel
timing chain must coincide with the injection pump gear retaining screws.
timing mark on the injection pump
gear.

Insert a 6mm drill bit through the hole in

the fuel injection pump gear and hand
tighten the pump gear retaining screws.

14. Remove the drill bits from the camshaft

gear holes and the injection pump gear.

12. NOTE: Check that the timing chain

tensioner is not under any tension.

Unlock the timing chain tensioner by

removing the pin.

15. Remove the special tool from the CKP

sensor bore.

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VEHICLE REPAIRS (CONTINUED)

16. NOTE: Install new rocker arm shaft retaining 18. Check camshaft timing by inserting 6mm
screws. drill bits through the holes in the
NOTE: The oil lubrication holes in the rocker camshaft gears and fuel injection pump
arm shafts must face downward. gear.
Install the rocker arm arrows.
• Tighten the screws in two stages:
• 1st stage: 13 Nm
• 2nd stage: 45 degrees

19. Check timing by inserting the special

tool through the CKP sensor bore.

17. Turn the crankshaft two turns to the

right.

20. Remove the special tool from the CKP

sensor bore.
21. Remove the drill bits from the camshaft
gear holes and the fuel injection pump
gear.
22. Install the CKP sensor. For more
information, see section 303-14.
23. Install the front engine cover. For more
information, refer to the procedure Front
Engine Cover - Vehicles with 75 PS
Engine
/ Front engine cover - Vehicles with 90 PS
or 120 PS engine included in this section.
24. Install the aiming cap. For more
information, see the procedure

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VEHICLE REPAIRS (CONTINUED)

Aiming cap included in this section.

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VEHICLE REPAIRS

Exhaust manifold (21 187 0)

Disassemb 4. Disconnect the positive crankcase

ly ventilation (PCV) hose from the
All vehicles
turbocharger compressor tube.
1. Disconnect the air filter outlet tube.

5. Remove the tube and oil dipstick.

• Discard the "O" ring seal.
2. Remove the air filter outlet tube.

3. Disconnect the charge air cooler intake 6. Raise and support the vehicle. For
pipe from the turbocharger. more information, see section 100-02.

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VEHICLE REPAIRS (CONTINUED)

7. Disconnect the oil return pipe from the 10. Remove the oil
turbocharger. feed pipe union.
• Discard the gasket. • Discard the sealing washers.

8. Remove the oil return pipe. 11. Remove the compressor tube from
1.Remove the oil return tube retaining the turbocharger.
screw. • Discard the "O" ring seal.
2.Remove the oil return pipe retaining
bracket.
3.Remove the oil return pipe.
• Discard the "O" ring seal.

12. Disconnect the front exhaust pipe from

the exhaust manifold and secure it to
the side.
• Discard the gasket.
9. Lower the
vehicle.

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VEHICLE REPAIRS (CONTINUED)
Vehicles with exhaust gas recirculation (EGR) Facility
system
13. Disconnect the EGR cooler from the All vehicles
exhaust manifold. 1. NOTE: Install new exhaust manifold studs, bolts
and nuts and all new gaskets and O-ring seals.
15.Vehicles with EGR
For installation, follow the disassembly
procedure in reverse order.

All vehicles
14. Remove the turbocharger and exhaust
manifold assembly.
• Discard the gasket, screws and nuts.

Remove the studs from the exhaust manifold.

• Discard the studs.

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VEHICLE REPAIRS (CONTINUED)

All vehicles

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VEHICLE REPAIRS

Cylinder head (21 163 0)

3. Remove the exhaust manifold. For more
Tools is specials
information, refer to the Exhaust Manifold
Dial Micrometer (Metric)
procedure included in this section.
205-069 (15-046)
4. Remove the camshafts. For more
? information, refer to the Camshafts
procedure included in this section.
5. Disconnect the air filter outlet tube.
Dial Micrometer Clamping
Stand 205-070 (15-022A)
"7 15022A

Cooling hose clamp

removal/installation tool
303-397 (24-003)
24003

Dial Micrometer Clamping

Stand 303-432 (21-183)
6. Remove the air filter outlet pipe.
< 21183

Given of
Fuel Injector
s Removal/Installation 303-677
303677 (21-236)

Fuel Injector Alignment Tool

303-711 (21-258)

(.
Denomination Specification
Loctite 7070

Disassembly
All vehicles
1. Drain the cooling system. For more information, refer to section 303-03.
2. Remove the alternator. For more information, refer to section 414-02.

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VEHICLE REPAIRS (CONTINUED)

7. Disconnect the intake pipe from the in- swimmer and power steering pump.
turbocharger charge air cooler.

8. Disconnect the coolant expansion tank 11. Remove the alternator mounting
hose and the upper radiator hose using bracket and power steering pump.
the special tool.

Vehicles with exhaust gas recirculation (EGR)

9. Separate the power steering pump from system cooler
the engine and set it aside (four screws). 12. Disconnect the coolant hose and separate
the EGR cooler from the cylinder head (-
engine shown removed for clarity).

10. Separate the alternator

wiring harness from the
engine lifting eye and the alternator
mounting bracket.
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VEHICLE REPAIRS (CONTINUED)

All vehicles 14. /! CAUTION: Remove the screws from

13. NOTE: The fuel injector locking sleeves the cylinder head in the sequence
must be completely released before the shown.
injectors can be removed.
Remove the cylinder head.
Loosen the locking sleeves on the fuel -
• Discard the gasket and screws.
injectors and remove the injectors by
gently loosening them.

Facility
All vehicles
1. Clean the mating surfaces of the cylinder
head and the monoblock with Loctite 7070.
2. Check cylinder head warpage. For more
information, refer to section 303-00.

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VEHICLE REPAIRS (CONTINUED)

3. NOTE: Measure the piston protrusion of 6. Z:CAUTION: Install new cylinder head
each cylinder at top dead center (TDC). bolts.
Install the cylinder head.
Measure the distance between the piston • Tighten the screws in the sequence shown
crown and the monoblock at the points in eight stages.
indicated. • Step 1: Tighten screws 1 to 10 to 10 Nm.
• Step 2: Tighten screws 11 to 18 to 5 Nm.
• Step 3: Tighten screws 1 to 10 to 20 Nm.
• Step 4: Tighten screws 11 to 18 to 10 Nm.
• Step 5: Tighten screws 1 to 10 to 40 Nm.
• Step 6: Tighten screws 11 to 18 to 20 Nm.
• Step 7: Tighten screws 1 to 10 to 180
degrees.
• Step 8: Tighten screws 11 to 18 to 180
degrees.

4. NOTE: The largest measurement determines

the cylinder head gasket selection.
Using the special tools, measure the
piston protrusion.

5. Determine the cylinder head gasket. For

more information, see the Specification
procedure included in this section.

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VEHICLE REPAIRS (CONTINUED)

7. Install the injectors using the special - 10. Attach the power steering pump to the
tools. engine (four screws).

Vehicles with EGR system cooler 11. Connect the coolant expansion tank
8. Connect the coolant hose and secure the hose and the upper radiator hose
EGR cooler to the cylinder head (engine using the special tool.
shown removed for clarity).

All vehicles 12. Connect the charge air cooler intake

9. Install the alternator and power steering pump pipe to the turbocharger.
mounting bracket.

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VEHICLE REPAIRS (CONTINUED)

13. Install the air filter outlet tube.

14. Connect the outlet tube to the air filter.

15. Install the camshafts. For more information, refer to the Camshafts
procedure included in this section.
16. Install the exhaust manifold. For more information, refer to the
Exhaust Manifold procedure included in this section.
17. Install the alternator. For more information, refer to section 414-02.
18. Fill and bleed the cooling system. For more information, refer to
section 303-03.

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VEHICLE REPAIRS

Oil pan (21 154 0)

4. Remove the oil pan retaining bolts (16

bolts).
Special tools
Oil pan separator
303-428 (21-179)
—

21179

Denomination Specification
Three M6 x 20mm guide
studs
Silicone sealant WSE-M4G323-A4

Engine oil WSS-M2C913-A1

5. /!CAUTION: Avoid deforming the
Disassembly crankcase.
oil.

1. Raise and support the vehicle. For more Separate the oil pan from the monoblock
information, see section 100-02. using the special tool.
2. Drain the engine oil. • Slide the special tool around the
3. NOTE: Inspect the oil pan drain plug seal crankcase profile.
for damage. Install a new seal and oil drain
plug if required.

Install the drain plug.

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VEHICLE REPAIRS (CONTINUED)

6. Remove the oil pump pickup tube. 4. Install the oil pump pickup tube.

7. Remove the oil pan. 5. NOTE: Do not fully tighten the crankcase
retaining bolts in this step.

Facility Install the oil pan (16 bolts).

• Remove the guide pins.
1. Install three M6 x 20 mm guide studs into
the crankcase to facilitate crankcase
installation.
2. CAUTION: Install the oil pan within 5
minutes after applying the sealant.
Apply a 3mm diameter bead of sealant to
the mating surface of the oil pan.

3. Place the oil pan on top of the

engine crossmember.

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VEHICLE REPAIRS (CONTINUED)

6. Tighten the crankcase retaining bolts.

• Tighten the screws in the sequence shown in two stages.
• 1st stage: Tighten screws 1 to 16 to 7 Nm.
• 2nd stage: Tighten screws 1 to 16 to 14 Nm.

ELE0015465

7. Lower the vehicle.

8. Fill the engine with oil.

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VEHICLE REPAIRS

Oil pump (21 714 0)

3. NOTE: The profile of the special tool must be

Special tools
in contact with the oil pump sprocket.
Oil pump alignment tool 303-
705 (21-256) Mount the special tool on the engine block
and hand tighten the two screws.
• Place the special tool against the oil pump
sprocket.
• Tighten the two screws.

303-682

Disassembly
1. Remove the oil pan. For more information,
refer to the Oil Pan procedure included in
this section.
2. NOTE: Please note that oil may leak out.
Gently pull on the chain to remove oil from
the tensioner.

4. Remove the oil pick-up pipe.

5. Remove the oil pump retaining bolts.

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VEHICLE REPAIRS (CONTINUED)

6. Remove the chain from the 2. NOTE: The profile of the special tool must
sprocket. be in contact with the oil pump sprocket.

Place the oil pump against the special

tool.
• Tighten the oil pump retaining bolts.

7. Remove the oil pump.

Facility
1. NOTE: Do not fully tighten the oil pump
retaining bolts in this step.
3. Disassemble the special tool.
Install the oil pump.
4. Install the oil pick-up pipe.
• Place the chain on the oil pump
sprocket.
• Hand tighten the oil pump retaining bolts.

5. Install the oil pan. For more information,

refer to the Oil Pan procedure included in
this section.

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VEHICLE REPAIRS

Rear crankshaft seal (21 468 4)

Disassembly
1. Remove the pressure plate and clutch disc. Facility
For more information, see section 308-01A.
2. Remove the flywheel. 1. NOTE: Replace the crankshaft rear oil seal
• Discard the screws. bracket and retaining bolts.
NOTE: The crankshaft rear oil seal bracket is
provided with an alignment sleeve that must be
removed after assembly.
NOTE: Do not fully tighten the crankshaft rear oil
seal bracket retaining bolts yet.
Install the crankshaft rear oil seal bracket.
2. Tighten the crankshaft rear oil seal bracket
retaining bolts.
• Tighten the screws in the order
indicated.

3. Remove the crankshaft rear oil seal

bracket.
• Discard the bracket and screws.

3. Remove the alignment sleeve from the

crankshaft rear oil seal bracket.

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VEHICLE REPAIRS (CONTINUED)

4. NOTE: Replace the flywheel bolts.

Install the flywheel.
• Tighten the screws in the order listed in
three stages.
• 1st stage: Tighten screws 1 to 8 to 25 Nm.
• 2nd stage: Tighten screws 1 to 8 to 40 Nm.
• 3rd step: Tighten screws 1 to 8 48 degrees.

5. Install the pressure plate and clutch disc.

For more information, see section 308-01A.

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DISASSEMBLY

DISASSEMBLY
Engine — Vehicles with Exhaust Gas Recirculation (EGR)

5. NOTE: Select neutral before removing the gear shift lever.

Special tools Remove the gear shift lever.
1.Pull the boot up.
Cooling hose clamp
2. Pull the plunger and remove the gear
removal/installation tool
shift lever.
303-397 (24-003)
3.Remove the insulator.

Workshop equipment

Engine lift
Hydraulic jack with wheels
Tripods
Transmission jack

Disassembly
All vehicles
1. A WARNING: When working on or near fuel
system components, do not smoke, leave
lit cigarettes, or open flames of any kind
nearby. Highly flammable mixtures are
always present and can ignite. Failure to 6. Remove the insulating pad from the gear
follow these warnings may result in injury. shift linkage.
Drain the cooling system. For more
information, refer to section 303-03.
2. Remove the accessory drive belt. For more
information, see section 303-05.
3. Remove the radiator grille housing panel. For
more information, refer to section 501-02.
4. Remove the catalytic converter. For more
information, see section 30900.

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DISASSEMBLY (CONTINUED)
7. Remove the base lever. 11. Remove the hood
gasket.

8. NOTE: Make sure the wiper motor is in the 12. NOTE: The windshield washer hose passes
rest position. through the cowl panel.
Remove the shell panel.
Remove the wiper arms. 1.Remove the lower retaining screws.
2.Detach the windshield washer hose.
3.Separate the clasps.

9. Remove the upper retaining screws from

the body panel.
• Remove the screw covers.
13. Remove the drain tube retaining clips.

10. Lift the chest.

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DISASSEMBLY (CONTINUED)

14. Remove the lower retaining screws 17. Remove the drain panel.
from the A-pillar outer trim panel.

18. Disconnect the coolant hoses from the

15. Remove the retaining screw from the thermostat housing using the special
wiper motor bracket. tool.

16. Remove the hood (four screws). 19. Remove the lower screw from the
radiator support.

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DISASSEMBLY (CONTINUED)
Vehicles with air conditioning All vehicles
20. Disconnect the electrical connector from 23. Disconnect the coolant expansion tank
the cooling fan hose and the lower radiator hose using
motor. the tool.
it's special.

Vehicles with exhaust gas recirculation

system
exhaust gas recirculation (EGR)
21. Disconnect the vacuum lines from the 24. Disconnect the charge air cooler intake
EGR vacuum regulator solenoid. pipe from the turbocharger.

22. Disconnect the electrical connector

from the EGR system vacuum Vehicles with EGR
regulator solenoid. 25. Disconnect the charge air cooler outlet
pipe from the EGR valve.

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DISASSEMBLY (CONTINUED)

All vehicles 30. Remove the exhaust hanger insulators

26. Raise and support the vehicle. For more and secure the exhaust to one side.
information, see section 100-02. Vehicles manufactured until 10/2001
4.25 tonne single cab chassis 31. NOTE: Mark the position of the driveshaft
27. Remove the lower protection from the flange in relation to the transmission output
front bumper. shaft flange.

Remove the driveshaft from the

transmission output shaft flange and set
it aside.

All vehicles
28. Separate the clutch slave cylinder from
the transmission.
Vehicles manufactured after 10/2001
32. NOTE: Mark the position of the driveshaft
flange in relation to the transmission output
shaft flange.
Remove the driveshaft from the
transmission output shaft flange and set it
aside.
• Discard the driveshaft flange
retaining screws.

29. Disconnect the electrical connectors

from the reverse light switch and the
vehicle speed sensor (VSS).

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DISASSEMBLY (CONTINUED)
All vehicles 36. Remove the radiator support bracket
33. Remove the transmission support and radiator.
insulator to front axle crossmember
bolts.

37. Using the drawing, develop a hand-

made tool.
34. Disconnect the horn electrical
connector.

38. Using a suitable transmission jack and

wooden blocks support the front axle.
35. Remove the right radiator support
bracket retaining screws.

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DISASSEMBLY (CONTINUED)

39. Loosen the front axle retaining screws 44. Separate the power steering pump from
approximately 20 mm. the engine and set it aside (four screws).

40. Install the hand-made tool.

• Tighten the front axle retaining screws. 45. Disconnect the coolant hose from the
water pump.

41. Remove the transmission jack. 46. Disconnect the electrical connector from the
42. Lower the vehicle. engine wiring
43. Disconnect the air filter outlet pipe from
the turbocharger.

harness.

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DISASSEMBLY (CONTINUED)
47. Remove the jump start connection 50. Disconnect the coolant hoses and
point cover. vacuum hoses from the heater core.

48. Disconnect the battery cable to the starter

solenoid and the alternator cable from the 51. Disconnect the engine ground cable
jump start connection point. from the side rail.

52. Disconnect the vacuum hose from the

49. Disconnect the fuel supply and return brake booster.
lines from the fuel filter.

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DISASSEMBLY (CONTINUED)

Vehicles with auxiliary heating 56. Install the rear engine lifting eye.
53. Disconnect the hoses from the auxiliary
heater.

57. Support the transmission using a

All vehicles suitable wheeled hydraulic jack.
54. Support the engine crossmember using a 58. Using a suitable engine lift, with the
suitable wheeled hydraulic jack. assistance of another technician, lower
the engine and transmission assembly
under the lifting eye and pull the engine
lift with the engine and transmission
assembly out of the engine
compartment.
59. Remove the vibration damper from the
engine crossmember.

55. Remove the engine crossmember

retaining bolts.

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DISASSEMBLY (CONTINUED)

60. Remove the engine crossmember.

61. Remove the right transmission retaining bolts.

62. Remove the left transmission retaining bolts.

63. L: CAUTION: Do not tilt the transmission during removal. This may damage the pilot
bushing.
Remove the transmission from the engine.

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DISASSEMBLY

Engine (21 134 8)

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2. Drain the engine.
• Allow the oil to drain into a suitable
container.
Special tools 3. NOTE: Inspect the crankcase drain plug seal
Mounting bracket for 303-435 for damage. Install a new oil pan seal and
(21-187) 303-435-06 (21- drain plug if required.

43
031B)

Install the drain plug.

Mounting plate for 303435-06

(21-031B) 303-435-011 (21-
146D)

PZ21146C

Front oil seal

removal/installation tool 303-

/6 or 679 (21-238)

303-679

4. Remove the dipstick tube and disconnect

Workshop the positive crankcase ventilation (PCV)
equipment hose from the bore cover.

Two
All spatulas
vehicles
1. Install the engine on the mounting stand.

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DISASSEMBLY (CONTINUED)
Vehicles with exhaust gas recirculation (EGR) All vehicles
system 7. Disconnect the oil feed pipe from the
5. Remove the EGR cooler pipe to the EGR turbocharger.
valve. • Discard the sealing washers.

6. NOTE: Take note of the position of the EGR 8. Remove the turbocharger and exhaust
cooler retaining clamp to the exhaust manifold assembly.
manifold to ensure it is reinstalled in the • Discard the gasket, screws and nuts.
correct position.

Remove the EGR system cooler.

• Discard the gasket and clamp.

9. Remove the studs from the exhaust

manifold.
• Discard the studs.

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DISASSEMBLY (CONTINUED)

Vehicles with EGR Vehicles without EGR

10. Disconnect the EGR valve electrical 13. Disconnect the fuel injection pump
connector. vacuum line from the intake manifold
tube.

11. Disconnect the intake air temperature

(IAT) sensor electrical connector. 14. Disconnect the electrical connectors
from the fuel shut-off solenoid and oil
pressure switch.

12. Disconnect the electrical connectors

from the oil pressure switch and fuel All vehicles
injection pump. 15. Disconnect the electrical connectors from
the glow plug wire and cylinder head
temperature (CHT) sensor.

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DISASSEMBLY (CONTINUED)
16. Remove the alternator mounting 18. Remove the oil cooler.
bracket and power steering pump. 1.Disconnect the hoses.
2.Remove the screws.

19. Remove the intake manifold (nine bolts).

ELE0015579

17. Remove the water pump.

1. Disconnect the hoses.
2. Remove the screws.
3. Discard the gasket. Vehicles with EGR
20. Remove the high pressure fuel supply
lines.
• Discard the fuel feed lines.

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DISASSEMBLY (CONTINUED)

21. Remove the return pipe from the fuel All vehicles
injectors. For more information, see 24. Disconnect the gas connector and the
section 310-00. engine coolant outlet.
• Discard the pipe and sealing washers. 1.Disconnect the gas hose.
• Discard the hose.
2.Remove the screws.
• Discard the "O" ring seal.

Vehicles without EGR

22. Remove the high pressure fuel supply
lines.
25. Remove the thermostat housing.

23. Remove the fuel return line from the 26. Remove the accessory drive belt idler
injectors. For more information, see pulley and cooling fan pulley.
section 310-00.

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DISASSEMBLY (CONTINUED)
27. Remove the crankshaft pulley using the 29. Remove the nuts and bolts from the
special tool. front engine cover.
• 2 nuts
• 20 screws

28. Using the special tool, remove the front

oil seal from the crankshaft.
• Discard the seal.

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DISASSEMBLY (CONTINUED)

30. /:CAUTION: Be careful not to deform the 32. Remove the rocker arm shafts.
front cover of the • Discard the screws.
engine.
CAUTION: Lubricate the spatulas with
engine oil several times during the
separating operation.
Remove the front engine cover using two
suitable spatulas.
• Use a spatula to facilitate the introduction
of the second one. Slide the second one on
the left around the profile of the front
engine cover.

ELE0015429
31. Remove the sight cover.
• Discard the stub cover gasket and stub
cover fuel injector seals. 33.Relieve tension and lock the timing
chain tensioner.
1.Retract the ratchet.
2.Push the locking device inwards.
3.Insert a pin.

ELE0012980

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DISASSEMBLY (CONTINUED)
34. Remove the timing chain tensioner 36. Remove the gears and timing chain.
and chain guides.

37. /! ATTENTION: Remove the screws

from thecarrier of the camshafts in the
sequence shown.
Remove the camshaft carrier.

35. Remove the fuel injection pump gear.

38. Remove the camshafts.

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DISASSEMBLY (CONTINUED)

39. NOTE: The fuel injector locking sleeves 41. Remove the fuel injection pump.
must be completely released before the
injectors can be removed. • Separate the fuel injection pump
Loosen the locking sleeves on the fuel - bracket from the engine.
injectors and remove the injectors by • Discard the gasket.
gently loosening them.

42. Remove the coolant distribution

manifold.
40. /!ATTENTION: Remove the screws from • Discard the gasket.
the cylinder head in sequence
shown.
Remove the cylinder head.
• Discard the gasket and screws.

43. Remove the crankcase mounting bolts.

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DISASSEMBLY (CONTINUED)

44. /! CAUTION: Avoid deforming the 46. Remove the oil pump pickup tube.
crankcase.
Remove the oil pan using a suitable
spatula.
• Slide the spatula around the profile of the
oil pan.

47. Remove the oil pump.

• Remove the chain from the
crankshaft gear.
45. Remove the oil pump chain tensioner.
1. Ease the tension on the chain.

2. Lock the tensioner by inserting a

pin.
3. Remove the screws.

48. Remove the crankshaft position

shaft (CKP). sensor.

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DISASSEMBLY (CONTINUED)

49. /:CAUTION: Loosen the clutch pressure 51. Remove the rear oil seal carrier from the
plate retaining screws two turns at a crankshaft.
time in the sequence shown. • Discard the carrier.
Ladder frame in the sequence
Remove the clutch disc and pressure
plate.

52. /!ATTENTION: Remove the screws

from theshown.
50. Remove the flywheel from the Disassemble the ladder frame.
engine. • Discard the gasket.
• Discard the screws.

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DISASSEMBLY (CONTINUED)

53. Remove the connecting rod bearing

caps.

54. Remove the pistons.

55. Remove the crankshaft main bearing
caps.

56. Remove the

crankshaft.

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DISASSEMBLY AND ASSEMBLY OF SUB-COMPONENTS

Cylinder head (21 165 6)

2. Remove the glow plugs.

Special tools
Socket wrench for cylinder
head temperature (CHT)
sensor 303-680 (21-239)

Fuel injector die

303-677 (21-236)

3. Remove the rear engine lifting eye.

Fuel Injector Alignment Tool

303-711 (21-258)

Disassemb
ly
1. Unplug the glow plug connectors.

4. NOTE: The fuel injector locking sleeves must

be completely loosened before the injectors
can be removed.
Loosen the fuel injector locking sleeves
and remove the injectors by gently
loosening them.

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DISASSEMBLY AND ASSEMBLY OF SUB-COMPONENTS (CONTINUED)

5. Using the special tool, remove the -

cylinder head temperature (CHT) sensor.

Mounti
ng
1. Assemble the components in the
reverse order of disassembly.
2.

6.

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 303-01A-97 Engine — Diesel Duratorq-Di/TDDi (Puma) 2.4L 303-01A-100
MOUNTING
Engine (21 134 8) Special tools
Fuel Injector Socket (21mm)

s
303-677 (21-236)
Tools is specials
Dial Micrometer (Metric)
205-069 (15-046)
7

Crankshaft oil seal

/either removal/installation tool 303-
679 (21-238)
Dial Micrometer Stand
205-070 (15-022A)
303-679

15022A Timing Cover Alignment Tool

Universal flange clamping 303-682 (21-241)
wrench
205-072 (15-030A)
G
(6 15030A
303-S82
Angle Gauge 303-174 (21-
Crankshaft Timing Tool 303-
540) 698 (21-251)

21540
303698
Crankshaft clearance gauge
Fuel Injector Alignment Tool
303-391 (21-166)
303-711 (21-258)
<0.

either.

Dial Micrometer Stand

303-432 (21-183) Workshop equipment
Engine lift ramp
Ruler
21183

Crankshaft TDC Timing Tool Ring compressor

303-675 (21-234) Three 6mm drill bits
Two M10 x 60 mm guide studs

303675

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303-01A-97 Engine — Diesel Duratorq-Di/TDDi (Puma) 2.4L 303-01A-101
ASSEMBLY (CONTINUED)

5. Install the crankshaft.

Denomination Specification
6. /:CAUTION: The main bearing cap screws
WSS-M2C913-A1
should only be used four times.
Engine oil - Vehicles NOTE: Mark screw heads with a center punch to
with exhaust gas indicate how many times they have been used.
recirculation (EGR) Install the crankshaft main bearing caps.
Engine oil - Vehicles WSS-M2C921-A • Tighten the screws in three stages in the
without EGR sequence shown.
Sealer WSE-M4G323-A4
Loctite 7070
Loctite 510 WSK-M2G348-A7
Sealer WSK-M2G350-A1

Mounting
All vehicles
1. Clean the mating faces of the cylinder head
and the monoblock with Loctite 7070.
2. Coat the crankshaft thrust half rings with
clean engine oil.
3. NOTE: The grooves in the crankshaft thrust
half-welds must face outwards.
Install the crankshaft thrust half-washers.
4. Coat the crankshaft and crankshaft bearing
shells with clean engine oil.

• 1st stage: 45 Nm
• 2nd stage: 80 Nm
• 3rd stage: 105
degrees

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7. Coat the cylinders with clean engine oil.

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ASSEMBLY (CONTINUED)

8. NOTE: Piston ring end clearances should be

evenly distributed around the circumference of
the piston. The elements of the oil control ring
must be arranged in the same way. Align the
piston ring end clearances 120 degrees to
each other.
Install the pistons using a suitable ring
compressor.

ELE0018513
9. Coat the connecting rod bearing shells with
clean engine oil.
10. ATTENTION: The connecting rod bearing
cap screws should only be used four
times.
NOTE: Mark screw heads with a center punch to
indicate how many times they have been used.
11. NOTE: Install a new reinforcement
intermediate pan gasket.
NOTE: Do not fully tighten the intermediate
crankcase retaining bolts and nuts yet.
Install the intermediate crankcase
reinforcement.

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Install the connecting rod bearing
caps.
• Tighten the screws in two stages:
• 1st stage: 30 Nm
• 2nd stage: 100 degrees

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ASSEMBLY (CONTINUED)

12. Z: ATTENTION: The intermediate Align the intermediate reinforcement sump

reinforcement crankcase and the with the monoblock using a suitable ruler.
monoblock must be aligned so that the 14. NOTE: Install a new seal carrier and
lateral clearance does not exceed 0.05 crankshaft rear oil seal carrier retaining bolts.
mm of overlap at 0.05 mm of clearance. NOTE: The crankshaft rear oil seal carrier is
Align the intermediate reinforcement sump supplied with an alignment sleeve that must be
with the monoblock using the special tool. removed after installation.
NOTE: Do not fully tighten the crankshaft rear oil
seal carrier retaining bolts at this stage.
Install the crankshaft rear oil seal carrier.
15. Tighten the crankshaft rear oil seal carrier
retaining bolts.
• Tighten the screws in the sequence shown.

13. A/N ATTENTION: The intermediate

reinforcement crankcase and the
monoblock must be aligned so that the
rear clearance does not exceed 0.01 mm
of overlap at 0.2 mm of clearance.
16. Remove the alignment sleeve from the
crankshaft rear oil seal carrier.

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ASSEMBLY (CONTINUED)

17. Tighten the intermediate crankcase 18. NOTE: Install new flywheel bolts.
reinforcement nuts and bolts. Install the flywheel.
• Tighten the nuts and bolts in the sequence • Tighten the screws in the sequence shown,
shown. in three stages.
• 1st stage: Tighten screws 1 to 8 to 25 Nm.
• 2nd stage: Tighten screws 1 to 8 to 40 Nm.
• 3rd stage: Tighten screws 1 to 8 48
degrees.

19. Install the special tools.

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ASSEMBLY (CONTINUED)
20. NOTE: Do not fully tighten the crankshaft 23. Set the dial micrometer to zero.
position sensor bracket retaining screws at this 24. Mark the position on the flywheel primary
stage. mass.
Install the crankshaft position (CKP) sensor
bracket.

25. NOTE: Rotate the crankshaft

counterclockwise.
21. NOTE: After installation do not move the Rotate the crankshaft until piston No. one
special tool. reaches zero on the dial micrometer.
Install the special tool. • Mark the position on the flywheel primary
mass.

22. Rotate the crankshaft until piston No. 26. Repeat the steps above to
one is approximately 10 mm before top ensure the marking is correct.
dead center (TDC).

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ASSEMBLY (CONTINUED)

27. NOTE: The middle part of the markings is

the TDC.
Measure the distance between the two
marks.

28. Divide the amount by two and mark the

TDC position on the flywheel primary
mass.
29. Measure the circumference of the
flywheel primary mass.
30. Multiply the circumference by 0.1388.
1.Mark the calculated amount on the primary
mass of the flywheel by measuring from
TDC to the left.
2. First brand.
3. Second brand.
4. PMS determined.
5.Determined 50 degrees before top dead
center (BTDC).

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31. NOTE: Rotate the crankshaft in the normal
direction of rotation to the calculated 50
degree BTDC mark.

Install the special tool.

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ASSEMBLY (CONTINUED)

32. Tighten the CKP sensor bracket retaining 36. NOTE: The largest measurement
screws. determines the cylinder head gasket selection.
Using the special tools, measure the piston
protrusion.

33. Disassemble the special tool.

34. Clean the contact face of the monoblock
and the piston with Loctite 7070.
35. NOTE: Measure the piston protrusion of 37. Determine the cylinder head gasket.
each cylinder at top dead center (TDC). 38. Install the pressure plate and clutch disc.
For more information, see section 308-
Measure the distance between the piston 01A.
crown and the monoblock at the points 39. NOTE: Do not fully tighten the oil pump
indicated. retaining bolts yet.
Install the oil pump and oil pump chain.

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ASSEMBLY (CONTINUED)

40. Using a suitable dial micrometer, take a 43. Install the oil pump chain tensioner.
reference measurement from the front 1. Install the screws.
face of the crankshaft gear. 2. Release the tensioner by removing the pin.
1. Place the dial micrometer holder on the
monoblock.
2. Place the dial micrometer plunger on the
crankshaft gear and set the dial
micrometer to zero.

44. Install the oil pump pickup tube.

41. NOTE: Take measurements at two different

points on the oil pump gear.
Using the dial micrometer, align the oil
pump gear and tighten the oil pump
retaining screws.

42. Check the alignment between the oil pump gear and the crankshaft gear. Repeat the
alignment process if necessary.

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ASSEMBLY (CONTINUED)

45. Z: CAUTION: Install the oil pan within 5 47. Tighten the crankcase mounting
minutes after applying the sealant. bolts.
Apply a 3mm diameter bead of sealant to • Tighten the screws in the sequence shown
the mating face of the oil pan. in two stages.
• 1st stage: Tighten screws 1 to 16 to 7 Nm.

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303-01A-97 Engine — Diesel Duratorq-Di/TDDi (Puma) 2.4L 303-01A-113

46. NOTE: Do not fully tighten the crankcase

mounting bolts in this step.

Install the oil pan.

ELE0015465

• 2nd stage: Tighten screws 1 to 16 to 14 Nm.

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ASSEMBLY (CONTINUED)

48. NOTE: Install a new coolant distribution / 2.. ...

manifold gasket. 2: ATTENTION: The Diesel injection
equipment is manufactured with very
Install the coolant distribution manifold.
precise tolerances and clearances. It is
therefore essential to maintain absolute
cleanliness when working with these
components. Always install blanking
plugs on all pipes or open holes.
50. NOTE: Do not tighten the fuel injection pump
support bracket to the block yet.
Install the fuel injection pump support
bracket to the block.

Vehicles with exhaust gas recirculation (EGR)

system
ATTENTION: Diesel fuel injection equipment
is manufactured with very precise
tolerances and clearances. Therefore, it
is essential to maintain absolute
cleanliness when working with these
components. Always install blanking
plugs on all pipes or open holes.
NOTE: If a new fuel injection pump is to be All vehicles
installed, it must be configured to the powertrain 51. NOTE: Install a new fuel injection pump
control module (PCM) using the WDS in order for gasket and O-ring seal.
the engine to be started. NOTE: Do not tighten the fuel injection pump
49. NOTE: Do not tighten the fuel injection pump support bracket bolts yet.
support bracket to the block yet. Install the fuel injection pump and
Install the fuel injection pump support loosely install the bracket bolts to the
bracket to the block. fuel injection pump.
Vehicles without EGR

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ASSEMBLY (CONTINUED)

52. Tighten the fuel injection pump 55. NOTE: Install a new cylinder head
retaining bolts. gasket as determined in the previous
steps.
Install the cylinder head gasket.

53. Tighten the fuel injection pump support

bracket to the block bolts (fuel injection
pump shown removed for clarity).

54. Tighten the bolts on the fuel injection

pump support bracket.

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ASSEMBLY (CONTINUED)

56. /:CAUTION: Install new cylinder 57. Install the fuel injectors using the
head bolts. special tools.
Install the cylinder head.
• Tighten the screws in the sequence
shown in eight stages.
• 1st stage: Tighten screws 1 to 10 to 20
Nm.
• 2nd stage: Tighten screws 11 to 18 to 10
Nm.
• 3rd step: Tighten screws 1 to 10 to 40 Nm.
• 4th step: Tighten screws 11 to 18 to 20
Nm.
• 5th step: Tighten screws 1 to 10 5
degrees. (180)
• 6th step: Tighten screws 6 to 11 18
degrees. (180) 58. Apply a 2.5 mm diameter bead of Loctite
510 to the gasket contact surface of the
cylinder head.

59. Install the camshafts.

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ASSEMBLY (CONTINUED)

60. Install the camshaft carrier. 61. Z: CAUTION: Do not rotate the crankshaft
• Tighten the screws in the sequence when the special tool is fully located
shown in two stages. inside the flywheel. Failure to follow
• 1st stage: Tighten screws 1 to 22 to 23 this warning may result in damage to
Nm. the CKP sensor bore.
NOTE: Only rotate the crankshaft in the normal
• 2nd stage: tighten screws 23 to 25 to 10
direction of rotation.
Nm.

Rotate the engine to 50 degrees BTDC

and insert the special tool through the
CKP sensor hole.

62. Z: ATTENTION: The copper links of the

timing chain must coincide with the
timing marks on the camshaft gears.

Install the camshaft gears and timing

ELE0013002
chain.

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ASSEMBLY (CONTINUED)

63. Insert the 6mm drill bits through the 65. Install the timing chain guides and
camshaft gear holes and hand tighten the tensioner.
gear retaining screws.

64. /:CAUTION: The copper links of the timing

chain must be aligned with the timing
marks on the injection pump gear.
NOTE: Do not tighten the injection pump gear
retaining screws yet.
Insert a 6mm drill bit through the hole in
the injection pump gear and into the
cutouts in the injection pump. Install the
injection pump gear retaining screws.

66. NOTE: Make sure that the timing chain

tensioner is not under any tension.

Unlock the timing chain tensioner by

removing the pin.

Vehicles without EGR

67. Turn the fuel injection
pump gear counterclockwise
to remove any slack in the chain.

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ASSEMBLY (CONTINUED)

timing and tighten the pump gear 68. ¿! CAUTION: Play in the timing
retaining screw. chain between the crankshaft
gear and the injection pump
timing chain gear can cause
injection pump timing failures.

Check that there is no play in the timing

chain between the crankshaft gear and
the injection pump gear.

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ASSEMBLY (CONTINUED)

All vehicles 72. NOTE: Install new rocker arm shaft

69. Tighten the camshaft gear and injection retaining screws.
pump gear retaining screws. NOTE: The rocker arm shaft oil feed holes
must point downward.

Install the rocker arm arrows.

• Tighten the screws in two
stages:
• 1st stage: 13 Nm
• 2nd stage: 45 degrees

70. Remove the drill bits from the camshaft

gear holes and the injection pump gear.

71. Remove the special tool from the CKP sensor bore.

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ASSEMBLY (CONTINUED)
73. NOTE: Rotate the crankshaft only in the 76. Remove the special tool from the CKP
normal direction of rotation. sensor bore.
77. Remove the drill bits from the camshaft
Turn the crankshaft two turns. gear holes and the injection pump gear.
78. Check the timing chain tension.

79. NOTE: Make sure the activator tooth is

visible through the bracket.
Install the CKP sensor.
• Install the CKP sensor over the trigger
tooth.
• Install the CKP sensor retaining screw.

74. Check camshaft timing by inserting 6mm

drill bits through the holes in the
camshaft gears and fuel injection pump
gear.

80. NOTE: Install a new rocker cover

gasket.
Install the rocker cover.

75. Check camshaft timing by inserting the -

special tool through the CKP sensor bore.

81. Install two M10 x 60 mm guide studs into

the monoblock to facilitate installation of
the front engine cover gasket.

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ASSEMBLY (CONTINUED)

82. Install a new front engine cover gasket. 84. Install the cover using the special tool.

83. CAUTION: Install the front engine cover

within five minutes after applying the
sealant.

Apply a 3mm diameter bead of sealant

to the front engine cover.

85. Remove the guide pins.

86. NOTE: The M6 x 14mm screws on the
front engine cover must be discarded and
new M6 x 16mm screws installed.
Install the front engine cover nuts and
bolts.
• 2 nuts
• 20 screws

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ASSEMBLY (CONTINUED)

87. NOTE: Install a new crankshaft front oil seal.

NOTE: The crankshaft front oil seal is provided with
an alignment sleeve that is removed during 89. Install the accessory drive belt idler
installation. pulley and cooling fan pulley.
Using the special tool, install the
crankshaft front oil seal.
st
V88 B 303-679 IA
,3 —5 9=-
DMS- 52252,- 1
ELE0015439
"gs"__c
—
ELE0015450

90. Install the thermostat housing.

88. ATTENTION: The crankshaft pulley retaining
bolts must be used a maximum of three
times.
i23 Nm
NOTE: Mark the screw heads with a center punch
according to the number of times they have been
i
used. —it is 28.6Nm X
Install the crankshaft pulley using the
special tool.
89/0204______,
• Tighten the screws in two stages:
• 1st stage: 30 Nm
9—( Iffnl Nm

• 2nd stage: 95 degrees

ELE001 5692888* -

EfeEe
| 205-072 7 n.

91. NOTE: Install a new coolant outlet connector

"O" ring seal and a new gas hose.
Connect the gas and coolant outlet
connector to the engine.
1.Install the screws.
ELE0015431
2.Connect the tube.

(1)— I 22 Nm

.6)2__
) ==(
Eu—x- g-----------

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 303-01A-97 Engine — Diesel Duratorq-Di/TDDi (Puma) 2.4L 303-01A-124
ASSEMBLY (CONTINUED)

92. NOTE: Install new fuel injector cap seals. 94. Connect the injector return line to the
Install the fuel injector seals to the thrust injectors.
cap using the special tool.

95. NOTE: Install new high pressure fuel feed

lines.
NOTE: Do not tighten the high pressure fuel feed
Vehicles with EGR line unions yet.
93. NOTE: Install a new fuel injector return line.
Install the fuel injector return line. Install the high pressure fuel supply
lines.

Vehicles without EGR

96. Install the fuel injector return line.

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 303-01A-97 Engine — Diesel Duratorq-Di/TDDi (Puma) 2.4L 303-01A-125
ASSEMBLY (CONTINUED)
ASSEMBLY (CONTINUED)
97. Connect the return line to the fuel - 100. NOTE: Do not tighten the high pressure fuel
injectors. feed line unions yet.
Vehicles without EGR
102. Tighten the high pressure fuel supply pipe Connect the high pressure fuel supply
connections to the fuel injection pump. lines to the fuel injectors.

104. NOTE: Install a new oil cooler O-ring

Q)9*Sx seal and oil filter.
Install the oil cooler.
K 25 Nm 1.Install the screws.
AW C 2.Connect the hoses.
1 X \ YO \ (K.-\J/
(2/ / _ Q_L epey ;(Tfl23 Nm yr AvSr L8 )
V )\/And 6/
\ 2—M©Nm/ 7- =12)8
BM12598. Install1the
7 high
/\ N pressure fuel supply lines. -..
- -—- - -X UEE A
\TO__A3K 23 Nm H 1 )
Vehicles with EGR
101. TightenIIthe
ELE0015682 s=-
high pressure fuel—supply
All vehicles
pipe connections to the fuel injection
103. NOTE: Install a new intake manifold gasket.
pump.
Install the intake manifold. 105. NOTE: Install a new water pump gasket.
Install the water pump.
~A 1.Install the screws.
2.Connect the hoses.
BfewX U JAHA'OHJ 7 r —,15Nm—E
ELE00154526D =— / V—Hll _ ---------- ks
- ExAATA (1)23
(2)4==
XN
All vehicles
99. NOTE: Do not tighten the high pressure fuel
NeN
REE-EE=( — \ //»
S§g£F-—
72
%n

feed line unions yet. ,8-/2/2559

1
Connect the high pressure fuel supply FAGlleFs—F
lines to the fuel injection pump. W/TsuC---AWW 23 Nm KJ
ffPAl
ELE0015684 I
OOlL/N- ii A

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ASSEMBLY (CONTINUED)
106. Install the alternator and power steering 108. Connect the glow plug wire electrical
pump mounting bracket. connector.

Vehicles with EGR

109. NOTE: Make sure the fuel injection pump
control unit electrical connector terminals are
clean.
Connect the electrical connector of the
fuel injection pump control unit.
• Slide the locking tab into position.

107. Connect the cylinder head temperature

(CHT) sensor electrical connector.

110. Connect the oil pressure switch

electrical connector.

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ASSEMBLY (CONTINUED)

111. Connect the intake air temperature (IAT) 114. Connect the fuel injection pump
sensor electrical connector. vacuum line to the intake manifold pipe.

112. Connect the EGR valve electrical All vehicles

connector. 115. Install new exhaust manifold studs.

Vehicles without EGR

113. Connect the electrical connectors of the 116. NOTE: Install a new gasket, nuts and exhaust
fuel shut-off solenoid valve and the oil manifold bolts
pressure switch.
Install the exhaust manifold and
turbocharger assembly.

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ASSEMBLY (CONTINUED)
117. NOTE: Install new oil feed tube sealing 120. Loosely install the EGR cooler to the
washers. cylinder head.
Connect the oil feed pipe to the
turbocharger.

121. NOTE: Make sure the EGR cooler to

exhaust manifold retaining clamp is installed
in the same position as it was before removal.
Vehicles with EGR
NOTE: Install a new EGR cooler retaining gasket
118. Loosen the screw securing the EGR
and clamp to the exhaust manifold.
cooler retaining bracket to the EGR
cooler. Loosely install the EGR cooler retaining
clamp to the exhaust manifold.

119. NOTE: Install a new EGR cooler tube to

the EGR valve.
Connect the EGR cooler pipe to the
EGR valve.

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ASSEMBLY (CONTINUED)

122. Loosely install the EGR cooler bolts 125. Tighten the EGR cooler bolts
to the EGR valve tube. to the EGR valve tube.

123. NOTE: To ensure uniform compression of 126. Tighten the EGR cooler retaining
the EGR cooler gasket to the exhaust bracket screw to the EGR cooler.
manifold, movement of the cooler must not
be restricted by any retaining screws.

Tighten the EGR cooler retaining clamp to

the exhaust manifold.

127. Connect the coolant hose to the EGR

cooler.

124. Tighten the EGR cooler retaining bracket

bolt to the cylinder head.

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ASSEMBLY (CONTINUED)
128. Connect the coolant hose to the EGR 133. Remove the engine mounting bracket.
cooler.

All vehicles
129. Connect the positive crankcase -
ventilation (PCV) system hose to the end
cap.

130. Install the oil dipstick tube.

131. Fill the engine with motor oil.

132. Using a suitable engine lift, remove the engine from the engine stand.

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FACILITY

Engine — Vehicles with Exhaust Gas Recirculation (EGR)

4. Install the left transmission retaining
Special tools bolts.

Cooling hose clamp

removal/installation tool
303-397 (24-003)

Workshop equipment
Engine lift ramp Hydraulic
jack with wheels Tripods

Denomination Specification 5. Install the right transmission retaining

bolts.
Fat WSD-M1C238-A
Facility
All vehicles
1. A/ WARNING: When working on or near fuel
system components, do not smoke,
leave lit cigarettes, or open flames of any
kind nearby. Highly flammable mixtures
are always present and can ignite.
Failure to follow these warnings may
result in injury.
Check the pilot bearing for damage. Install a
new pilot bearing if necessary. For more
information, see section 308-01A.
2. CAUTION: Do not apply grease to a newly 6. Install the engine
mounted pilot bearing. crossmember.
Apply approximately one gram of grease to
the used pilot bearing.
3. Z CAUTION: Do not tilt the transmission
during assembly. The pilot bearing could
be damaged.
Install the transmission to the engine.

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INSTALLATION (CONTINUED)
7. Install the vibration damper to the engine 11. Install the engine crossmember
crossmember. retaining bolts.

8. Using a suitable engine lift, with the 12. Z: WARNING: Make sure the rear engine
assistance of another technician, lower lifting eye has been removed as it
the engine and transmission assembly may come into contact with the brake
under the towing eye and push the engine pipe. Failure to follow this warning
lift with the engine and transmission may result in injury.
assembly into the engine compartment.
9. Lower the engine lift and support the
engine crossmember and transmission on
suitable tripods. Remove the rear engine lifting eye (if
10. Raise the engine by supporting the equipped).
engine cross member on a suitable - • Store the ring in the workshop for later
wheeled hydraulic jack. use.

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INSTALLATION (CONTINUED)
Vehicles with auxiliary heater 16. Connect the coolant hoses and vacuum
13. Connect the auxiliary heater hoses. hoses to the heater.

17. Connect the fuel supply and return

All vehicles lines to the fuel filter.
14. Connect the vacuum hose to the brake
booster.

18. Connect the battery cable to the starter

15. Connect the engine ground wire to solenoid and the alternator cable to the
the frame rail. jump starter connection point.

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303-01A-124 Engine — Diesel Duratorq-Di/TDDi (Puma) 2.4L 303-01A-135
INSTALLATION (CONTINUED)
19. Install the jumper cable jumper 22. Attach the power steering pump to the
connection point cover. engine (four screws).

20. Connect the engine wiring harness 23. Connect the air filter outlet pipe to the
electrical connector. turbocharger.

21. Connect the coolant hose to the water 24. Raise and support the vehicle. For
pump. more information, see section 100-02.
25. Disassemble the handmade tool.

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INSTALLATION (CONTINUED)
26. Tighten the front axle retaining screws. 29. NOTE: Make sure the clutch slave cylinder
actuator rod properly engages the clutch
release lever.

Attach the clutch slave cylinder to the

transmission.

27. Install the transmission support insulator

bolts to the front axle crossmember.

Vehicles manufactured after 10/2001

30. NOTE: Align the mark on the driveshaft
flange with the mark on the transmission
output shaft flange.
NOTE: Install new driveshaft to transmission
output shaft flange bolts.

Attach the driveshaft to the

transmission output shaft flange.

Vehicles manufactured until 10/01

28. NOTE: Align the mark on the driveshaft
flange with the mark on the transmission
output shaft flange.
Attach the driveshaft to the
transmission output shaft flange.

All vehicles
31. Install the
exhaust.

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INSTALLATION (CONTINUED)
32. Connect the electrical connector of the 4.25 tonne single cab chassis
reverse light switch and the vehicle 35. Install the front bumper underguard.
speed sensor (VSS).

33. Install the radiator and radiator support All vehicles

(four screws). 36. Lower the vehicle.
Vehicles with exhaust gas recirculation (EGR)
system
37. Connect the EGR cooler outlet pipe to
the EGR valve.

34. Connect the horn electrical connector.

All vehicles
38. Attach the charge air cooler inlet pipe to
the turbocharger.

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 303-01A-124 Engine — Diesel Duratorq-Di/TDDi (Puma) 2.4L 303-01A-138
INSTALLATION (CONTINUED)
Vehicles with EGR lower radiator using the special tool.
39. Connect the EGR vacuum regulator
solenoid electrical connector.

43. Install the lower radiator mounting

40. Connect the vacuum lines to the EGR bracket screw.
vacuum regulator solenoid.

44. Connect the coolant hoses to the

Vehicles with air conditioning thermostat housing using the special
41. Connect the cooling fan motor electrical tool.
connector.

All vehicles
42. Connect the coolant expansion tank hose and the inlet hose.

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 303-01A-124 Engine — Diesel Duratorq-Di/TDDi (Puma) 2.4L 303-01A-139
INSTALLATION (CONTINUED)

45. Install the drain panel. 48. Install the lower A-pillar exterior
trim panel retaining screws.

49.

46. Install the

chest.

47. Install the wiper motor bracket retaining

screw.

Install the drain tube retaining clips.

50. NOTE: The windshield washer hose passes through the cowl panel.
Install the shell panel.
1. Fasten the clasps.
2. Connect the windshield washer hose.

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303-01A-124 Engine — Diesel Duratorq-Di/TDDi (Puma) 2.4L 303-01A-140
3. Install the lower retaining screws.

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INSTALLATION (CONTINUED)
51. Install the upper shell panel 54. NOTE: The rough side of the insulating
retaining screws. padding must face up.
• Replace the screw covers. Install the shift linkage insulator pad.

52. Install the wiper arms.

55.Install the gear shift lever.
1.Install the insulation.

2.Install the gear shift lever until the plunger

locks.
3.Install the boot.

DEE0012807

53. Install the short speed shift lever.

56. Install the catalytic converter. For more

information, see section 309-00.
57. Install the radiator grille housing panel.
For more information, refer to section
501-02.
58. Install the accessory drive belt. For more
information, see section 303-05.
59. Fill and bleed the cooling system. For
more information, refer to section 303-
03.
60. Remove the crankshaft position (CKP)
sensor. For more information, refer to
section 303-14.

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303-01A-124 Engine — Diesel Duratorq-Di/TDDi (Puma) 2.4L 303-01A-142
INSTALLATION (CONTINUED)
61. / CAUTION: Do not turn the engine when
the crankshaft pulley and the front engine
the special tool is located completely
cover.
inside the flywheel. Failure to follow
67. Disconnect the fuel filter return line to the
this warning may result in damage to
filter injection pump. For more
the CKP sensor bore.
information, refer to section 310-00.
NOTE: Rotate the engine only in the normal
engine rotation direction.
Rotate the engine to 50 degrees before
top dead center (TDC) and insert the
special tool through the CKP sensor hole.

68. Make and install a bleed tube as shown,

using clear plastic tubing and suitable
connectors.

1.Connect the bleed tube to the fuel

injection pump return line.
62. Using a suitable paint, mark the position 2.Connect the bleed tube to the fuel filter.
of the crankshaft pulley relative to the 3.Place the bleed tube in a suitable
front engine cover. container.

63. Remove the special tool from the CKP

sensor bore.

Vehicles with 120 HP diesel engine

64. Install the CKP sensor. For more 69. Disconnect the electrical connector from
information, see section 303-14. the fuel feed
65. Connect the battery ground cable. For pump.
more information, see section 414-01.
66. Check if the engine continues at 50
degrees before TDC by the timing marks.

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INSTALLATION (CONTINUED)
70. Using a 15 A fused jumper wire, supply 74. NOTE: If a new fuel injection pump has been
battery voltage and a good ground installed and fuel flow through the high
connection to the fuel pump electrical pressure system is not adequate, the new
connector to activate the fuel pump. pump must be configured to the PCM using
the WDS to allow the high pressure fuel
supply lines to be purged.
Make sure the engine is still at 50
degrees before TDC by checking the
paint marks.
Vehicles with 120 HP diesel engine
75. Using a 15A fused jumper wire, supply
battery voltage and a good ground
connection to the fuel pump electrical
connector to activate the fuel pump.

Vehicles with 75 HP or 90 HP diesel engines

71. NOTE: The manual fuel priming pump is
located above the fuel filter.
Operate the manual fuel priming pump
and inspect the bleed tube for signs of
air.
All vehicles
72. When the airless fuel has passed into the
tank, remove the bleed tube.
73. Install a clear plastic tube as shown.
1.Connect the clear plastic tube to the fuel
injection pump return line. 76. NOTE: Only one of the high pressure fuel
2.Connect the clear plastic tube to the fuel supply lines will show signs of fuel leaks.
filter.
Visually inspect the high pressure fuel
supply lines and tighten the pipe joint
that shows signs of fuel leaks.

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INSTALLATION (CONTINUED)
Vehicles with 75 HP or 90 HP diesel engines All vehicles
77. NOTE: Only one of the high pressure fuel 81. NOTE: Make sure that it is still possible to
feed lines will show signs of fuel leaks. move one half of the high pressure fuel supply
Operate the manual fuel priming pump line support bracket without moving the other
(located on top of the fuel filter) and half.
tighten any high pressure fuel line NOTE: Do not tighten the high pressure fuel feed
fittings where fuel leaks are detected. line support bracket nuts to the high pressure fuel
feed line at this time.
Install the support bracket on the high
pressure fuel feed line to the high
pressure fuel feed lines.

All vehicles
78. NOTE: Rotate the crankshaft only in the
normal direction of rotation.
Using the paint mark as a reference,
slowly rotate the crankshaft 180 82. NOTE: Do not tighten the high pressure fuel
degrees. supply line support bracket to the cylinder
Vehicles with 120 hp diesel engine 79. Repeat head screw yet.
steps 63 through 65 to bleed the three install the high pressure fuel feed line
remaining high pressure fuel supply lines. support bracket bolt to the cylinder head.
Vehicles with 75 HP or 90 HP diesel engines.
Repeat steps 64 and 65 to bleed the three
remaining high pressure fuel supply lines.

83. Tighten the high pressure fuel feed line -

support bracket retaining nuts to the

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INSTALLATION (CONTINUED)

high pressure fuel supply lines. Vehicles with 120 HP diesel engine
86. Remove the jumper wire and connect the
fuel pump electrical connector.
All vehicles
87. Start the engine and gently increase the
engine speed to 1,000 rpm for
approximately 2 to 3 minutes until no air
is visible in the clear plastic tube.
88. Turn off the engine.
89. Remove the clear plastic tube.
90. Connect the fuel return line from the fuel
injection pump to the fuel filter to the fuel
filter.

84. Tighten the bolt on the support bracket for

the high pressure fuel supply line to the
cylinder head.

85. Tighten the two halves of the high

pressure fuel feed pipe support
bracket.

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