303-01A-Engine - 2.4L Duratorq-Tdci (Puma) Diesel 303-01A

303-01A-1 Engine — 2.
4L Duratorq-TDCi (Puma) Diesel 303-01A-1

.
SECTION 303-01A Engine — 2.4L Duratorq-TDCi

(Puma) Diesel
VEHICLE APPLICATION:2007.50 Transit
CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 303-01A-3
Engine Data — 100 PS................................................................................................... 303-01A-3
Engine Data — 115 PS................................................................................................... 303-01A-3
Engine Data — 140 PS................................................................................................... 303-01A-3
Engine Oil Capacity........................................................................................................ 303-01A-4
Cylinder Block Dimensions............................................................................................. 303-01A-4
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Piston Dimensions.......................................................................................................... 303-01A-4
Crankshaft Dimensions................................................................................................... 303-01A-4
Connecting Rod Dimensions.......................................................................................... 303-01A-5
Piston Pin Dimensions 100 PS....................................................................................... 303-01A-5
Piston Pin Dimensions 115 PS and 140 PS................................................................... 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-7
DIAGNOSIS AND TESTING

Engine................................................................................................................................. 303-01A-11
IN-VEHICLE REPAIR
Intake Manifold............................................................................................... (21 183 0) 303-01A-12
Valve Cover.................................................................................................... (21 141 0) 303-01A-13
Crankshaft Front Seal..................................................................................... (21 467 0) 303-01A-14
Engine Front Cover........................................................................................ (21 148 0) 303-01A-16
Valve Springs...................................................................................................................... 303-01A-21
Valve Seals..................................................................................................... (21 238 0) 303-01A-23
Valves............................................................................................................. (21 215 4) 303-01A-24
Camshafts...................................................................................................... (21 284 0) 303-01A-26
Exhaust Manifold............................................................................................ (21 187 0) 303-01A-31
Cylinder Head................................................................................................. (21 163 0) 303-01A-33
Oil Pan............................................................................................................ (21 154 0) 303-01A-37
Oil Pump......................................................................................................... (21 714 0) 303-01A-39
Crankshaft Rear Seal..................................................................................... (21 468 4) 303-01A-41
REMOVAL
Engine................................................................................................................................. 303-01A-43
303-01A-2 Engine — 2.4L Duratorq-TDCi (Puma) Diesel 303-01A-2
.
DISASSEMBLY
Engine................................................................................................................................. 303-01A-48
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Cylinder Head................................................................................................. (21 165 6) 303-01A-55
ASSEMBLY
Engine................................................................................................................................. 303-01A-57
INSTALLATION
Engine................................................................................................................................. 303-01A-65
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SPECIFICATIONS
Engine Data — 100 PS
Description
Code PHFA
Firing order 1-3-4-2
Bore diameter 89.9 mm
Stroke 94.6 mm
Displacement 2402 cc
Compression ratio 17.5:1
Power output at 3500 rpm 74 kW (100 PS)
Torque between 1600 to 2200 rpm 285 Nm
Idle speed 750 rpm
Maximum oil consumption 0.1L /1000 Km
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Description
Code JXFA
Stroke 94.6 mm
Idle speed 750 rpm

Description
Code H9FB
Stroke 94.6 mm
Idle speed 750 rpm
2007.50 Transit 11/2006 G552703en

SPECIFICATIONS
Engine Oil Capacity
Description Liters
Initial fill including oil filter 7.20
Service fill including oil filter 6.86
Cylinder Block Dimensions

Description mm
Cylinder bore diameter — Class 1 89.900 - 89.910
Main bearing shells 1 to 4 inner diameter — bearings installed 65.003 - 65.030
Main bearing shell 5 inner diameter — bearings installed 70.004- 70.033
Main bearings 1 to 4 radial clearance 0.005 - 0.051
Main bearing 5 radial clearance 0.004 - 0.054
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Main bearings 1 to 4 parent bore diameter — vertical measurement 69.504 - 64.520
Main bearing 5 parent bore diameter — vertical measurement 74.504 - 74.520
Main bearings 1 to 4 parent bore diameter — horizontal measurement 69.502 - 69.525
Main bearing 5 parent bore diameter — horizontal measurement 74.502 - 74.525
Piston Dimensions
Description mm
Piston diameter — Class 1 89.84 - 89.85
Piston clearance in cylinder 0.05 - 0.07
Piston ring end gaps
— upper compression ring 0.25 - 0.40
— lower compression ring 0.50 - 0.75
— oil control ring 0.25 - 0.50
Piston ring gap position: The piston ring end gaps must be distributed evenly around the circumference of the piston. This also
applies to the oil control ring elements. Align the piston ring end gaps at 120 degrees to each other.
Crankshaft Dimensions
Description mm
Main bearing journal end float 0.090 - 0.305
Main bearing journals 1 to 4 diameter 64.950 - 64.970
Main bearing journal 5 diameter 69.950 - 69.970
Connecting rod bearing journal diameter 52.980 - 53.000
2007.50 Transit 11/2006 G552703en

SPECIFICATIONS
Connecting Rod Dimensions
Description mm
Large end bore diameter 55.096 - 56.015
Small end bore 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 100 PS

Description mm
Piston pin length 66.00
Piston pin diameter 32.000
Piston pin slide clearance 0.008 - 0.018
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Piston Pin Dimensions 115 PS and 140 PS
Description mm
Piston pin length 70.95
Piston pin diameter 32.000
Piston pin slide clearance 0.008 - 0.018
Camshaft Dimensions
Description mm
Camshaft end float 0.014 - 0.200
Camshaft bearing journal diameter 26.450
Camshaft bearing clearance — radial measurement 0.065
Valve Dimensions
Description mm
Valve stem to valve guide clearance — intake valve 0.045
Valve stem to valve guide clearance — exhaust valve 0.055
Cylinder Head Dimensions

Description mm
Maximum distortion — measured longitudinally and diagonally 0.10
Peak to valley height of mating surface 0.02
Cylinder head gasket thickness
Piston protrusion of 0.310 - 0.400 mm 1.1 (one hole/tooth)
Piston protrusion of 0.401 - 0.450 mm 1.15 (two holes/teeth)
Piston protrusion of 0.451 - 0.500 mm 1.2 (three holes/teeth)
2007.50 Transit 11/2006 G552703en

SPECIFICATIONS
Oil Pressure Specifications
Description bar
Minimum oil pressure at idle speed 1.25
Minimum oil pressure at 2000 rpm 2.0
Lubricants, Fluids, Sealers and Adhesives

Item Specification
Ford Formula E SAE 5W-30 engine oil WSS-M2C913-B
Sealer — oil pan, camshaft carrier and engine front cover WSE-M4G323-A4
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2007.50 Transit 11/2006 G552703en

Engine
General view
• The 2.4L Duratorq-TDCi (Puma) diesel engine
is available in three different power output
versions: 74 kW (100 PS), 85 kW (115 PS) and
103 kW (140 PS). 1
• The 2.4L engines are equipped with the Denso
common rail fuel system.
• The service interval is 25,000 km or one year
for all versions other than the 140 PS version.
• The service interval for the 140 PS version is 3 2
50,000 km or two years. A service interval TIE0031809
indicator in the instrument cluster alerts the
driver when servicing is required. Item Description
• The 74 kW (100 PS) version is the entry-level 1 Engine serial number
version for the rear wheel drive vehicles.
2 Vehicle identification number
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• The 85 kW (115 PS) version additionally has oil
spray nozzles for cooling the piston crowns as 3 Engine code
well as fuel injector nozzles with an increased
flow rate. Engine identification plate
• The 103 kW (140 PS) version has an electrical
actuator for turbocharger guide vane
adjustment, an oil level/temperature sensor as
well as a centrifugal oil filter.
Engine identification code

On the 2.4L engine the engine code (4 digits) and
the engine serial number (2 letters for the year and
month and 5 figures for the serial number) are
stamped in the cylinder block on the exhaust side
(in line with cylinder No. 4).
TIE0031810
If the engine or cylinder block is changed, the
vehicle identification number must be stamped in
The engine identification plate is located on the
the indicated location.
cover of the timing cover. It contains the following
data:
• date and time of manufacture
• engine part number
Engine management
Visteon
Engine emission control

Meets emission standard Stage IV
Electrical Exhaust Gas Recirculation (EGR) valve
with water cooling
Diagnostics
Worldwide Diagnostic System (WDS)
2007.50 Transit 11/2006 G552704en

Technical data 2.4L Duratorq-TDCi
(Puma) Diesel
2.4L Duratorq-TDCi
(Puma) Diesel Firing order 1-3-4-2
Engine code 74 kW PHFA Engine idle speed 750 rpm
(100 PS) Max. power output, 74 kW (100 PS) at
Engine code 85 kW JXFA torque 3,500 rpm, 285 Nm at
(115 PS) 1,600 rpm
Engine code 103 kW H9FB Max. power output, 85 kW (115 PS) at
(140 PS) torque 3,500 rpm, 310 Nm at
1,750 rpm
Cubic capacity 2,402 cc
Max. power output, 103 kW (140 PS) at
Stroke 94.6 mm torque 3,500 rpm, 375 Nm at
Bore diameter 89.9 mm 2,000 rpm
Compression ratio 17.5:1 Fuel Diesel
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Power and torque curves
380 130
360 120
1
340 110
2
320 3 100
300 4 90
280 80
260 70
A 6 C
240 60
5
220 50
200 40
180 30
160 20
140 10
120 0
1000 1500 2000 2500 B 3000 3500 4000 4500
E68431
Item Description Item Description

A Torque (Nm) 2 Power curve for 103 kW (140 PS) engine
B Engine speed (rpm) 3 Torque curve for 85 kW (115 PS) engine
C Power output (kW) 4 Power curve for 85 kW (115 PS) engine
1 Torque curve for 103 kW (140 PS) engine
2007.50 Transit 11/2006 G552704en

Item Description Centrifugal oil filter (140 PS version only)
5 Torque curve for 74 kW (100 PS) engine
6 Power curve for 74 kW (100 PS) engine
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E68324
Item Description The oil from the oil pan is pumped into the rotor
via an additional pressure line installed on the
1 Cover cap
outside of the engine block. Inside the rotor is a
2 Centrifuge (under the valve cover) pivot axis with two outlet openings on opposite
sides.
3 Oil pressure line to the centrifugal oil filter
The oil pressure and the shape of the rotor cause
The 140 PS version of the 2.4L Duratorq-TDCi this pivot axis to turn, forcing the oil in the rotor
(Puma) diesel engine has a centrifugal oil filter that outwards. The centrifugal force presses the
in conjunction with the oil level/temperature sensor particles floating in the oil (contamination) against
facilitates a service interval of up to 50,000 km. the outer wall of the rotor, where they form a solid
The centrifugal oil filter is located in the cylinder mass.
head and comprises: The oil in the rotor is filtered in this manner and
– a cover cap (in the valve cover) then flows back into the oil circuit.
– a replaceable rotor (filter element) The centrifugal oil filter can even catch small
particles of dirt that cannot be filtered using normal
oil filters. This increases the service life of the oil.
Oil level/temperature sensor (140 PS version only)
2007.50 Transit 11/2006 G552704en

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2
3
E64597
Item Description The PCM calculates the next oil change on the
basis of an integrated strategy (which also takes
1 Oil level/temperature sensor
into consideration the mileage and engine
2 Openings operating conditions) and displays it in the
instrument panel.
3 Engine oil dipstick
In addition, a separate indicator in conjunction with
An oil level/temperature sensor located on the front a corresponding message in the instrument cluster
of the engine directly beside the engine oil dipstick display warns the driver when the oil quantity falls
is provided for the service interval indicator. below the minimum level.
A wire coil that is fitted inside the sensor and Service instruction
continuously supplied with current is used to
measure the oil level. The interval indicator must be reset after an oil
change on all vehicles with a diesel engine.
The resistance of the wire coil changes according
to how deeply the sensor is immersed in the oil. In the case of the 103 kW (140 PS) version it must
The measurement values are registered by the be ensured that the vehicle is standing on a flat
Powertrain Control Module (PCM). surface.
The change in the voltage drop serves as an input
variable for calculating the oil level.
The oil temperature is sensed simultaneously via
the integrated temperature sensor. The
temperature is used as a corrective factor in the
calculation.
2007.50 Transit 11/2006 G552704en

DIAGNOSIS AND TESTING
Engine
REFER to Section 303-00 [Engine System -
General Information].
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2007.50 Transit 11/2006 G17645en

IN-VEHICLE REPAIR
Intake Manifold (21 183 0)

Removal
5. Remove the engine oil filler pipe.
1. Disconnect the battery ground cable.
For additional information, refer to:Battery
Disconnect (414-01 Battery, Mounting and
Cables, General Procedures).
2. Slide open the bolt cover.
VUE0013014
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6. Remove the intake manifold.
VUE0014625 25 Nm
x9
3. Remove the accessory drive belt shield x2

retaining bolts. 10 Nm
E75765
Installation
1. NOTE:Install a new intake manifold gasket.
To install, reverse the removal procedure.
VUE0013013
4. Detach the fuel charging wiring harness and

remove the accessory drive belt shield.
VUE0014626
2007.50 Transit 11/2006 G552648en

IN-VEHICLE REPAIR
Valve Cover (21 141 0)

General Equipment 1. Discard the studs.
Pneumatic Vacuum Gun
Removal 10 Nm 1
WARNING:Do not smoke or carry lighted

tobacco or open flame of any type when x4
working on or near any fuel related
components. Highly flammable mixtures
are always present and may ignite. Failure 10 Nm
to follow these instructions may result in x10
personal injury. E75679
CAUTION:Diesel fuel injection equipment
is manufactured to very precise tolerances
Installation
and fine clearances. It is therefore essential
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that absolute cleanliness is observed when 1. NOTE:Install a new valve cover gasket as
working with these components. Always necessary.
install blanking plugs to any open orifices
or lines. To install reverse the removal procedure.
1. Remove the fuel injectors.
For additional information, refer to:Fuel
Injectors (303-04 Fuel Charging and
Controls - 2.4L Duratorq-TDCi (Puma)
Diesel, Removal and Installation).
2. Disconnect the cylinder head temperature
(CHT) sensor electrical connector.
VUE0015709
3. Remove the valve cover.
2007.50 Transit 11/2006 G552705en

IN-VEHICLE REPAIR
Crankshaft Front Seal (21 467 0)

Special Tool(s) • Discard the seal.
Flange Holding Wrench,
Universal
205-072 (15-030A)
303-679
15030A
Remover/Installer, Crankshaft
Front Oil Seal
303-679 (21-238)
ELE0015434
Installation
303679
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1. NOTE:Install a new crankshaft front oil seal.
NOTE:A new crankshaft front oil seal is supplied
Removal with an alignment sleeve that will be pushed out
during installation.
1. Remove the accessory drive belt. For
additional information, refer to Using the special tool, install the crankshaft
Section 303-05 [Accessory Drive]. front oil seal.
2. Raise and support the vehicle. For additional
information, refer to Section 100-02 [Jacking
and Lifting].
3. Using the special tool, remove the crankshaft
pulley.
303-679
205-072 ELE0015449
2.
CAUTION:Crankshaft pulley retaining
205-072-01 bolts must only be used three times.
ELE0015430 NOTE:Stamp the crankshaft pulley retaining bolt
heads with a center punch to indicate usage.
Using the special tool, install the crankshaft
4. Using the special tool, remove the crankshaft
pulley.
front oil seal.
• Tighten the bolts in two stages.
• Stage 1: 30 Nm.
2007.50 Transit 11/2006 G25485en

IN-VEHICLE REPAIR
• Stage 2: 95 degrees.
205-072
205-072-01
ELE0015430
3. Lower the vehicle.

4. Install the accessory drive belt. For
additional information, refer to
Section 303-05 [Accessory Drive].
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2007.50 Transit 11/2006 G25485en

IN-VEHICLE REPAIR
Engine Front Cover (21 148 0)

Special Tool(s)
Lockin Tool, Flywheel Removal
303-393
1. Drain the cooling system. For additional
information, refer to:(303-03 Engine Cooling)
Cooling System Draining, Filling and
21168
Bleeding - 2.2L Duratorq-TDCi (Puma)
Diesel/2.4L Duratorq-TDCi (Puma) Diesel,
Vehicles With: Fuel Fired Booster Heater
Separator, Oil Pan (General Procedures),
303-428 (21-179) Cooling System Draining, Filling and
Vehicles Without: Fuel Fired Booster
21179 Heater (General Procedures).
2. Remove the cooling fan motor and shroud.
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Remover/Installer Crankshaft For additional information, refer to:Cooling
Front Oil Seal Fan Motor and Shroud (303-03 Engine
303-679 Cooling, Removal and Installation).
3. Remove the starter motor.
For additional information, refer to:Starter
Motor - 2.4L Duratorq-TDCi (Puma) Diesel
303679
(303-06 Starting System, Removal and
Installation).
Aligner, Front Cover
303-682 4. Install the special tool.
303682
303-393
Holding Wrench, Crankshaft

303-1177
E62044 E75705
General Equipment 5. Detach the water pump and the brake

vacuum pump from the engine and position
Spatula them to one side (four bolts).
Two M10 x 60 mm locating studs
Materials
Name Specification
Sealer WSE-M4G323-A4
2007.50 Transit 11/2006 G552706en

IN-VEHICLE REPAIR
• Discard the gasket. 8. Remove the accessory drive belt idler pulley
and the cooling fan pulley.
ELE0005748
ELE0015438
6. Detach the thermostat housing support
bracket from the cylinder head and 9. Using the special tool, remove the crankshaft
disconnect the radiator upper hose from the pulley.
thermostat housing.
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303-1177
E63363
ELE0015436
10. Using the special tool, remove the

7. Disconnect the coolant outlet and degas crankshaft front oil seal.
connector from the engine.
• Discard the seal.
1. Disconnect the degas hose.
• Discard the hose.
2. Remove the bolts.
303-679
• Discard the O-ring seal.
ELE0015435
2 11. Remove the engine front cover nuts and

bolts.
TIE0015679
• 2 nuts.
2007.50 Transit 11/2006 G552706en

IN-VEHICLE REPAIR
• 20 bolts. 3. Install a new engine front cover gasket.
ELE0015440
ELE0015442
12. NOTE:Lubricate the spatula with clean 4.

engine oil. CAUTION:Install the engine front cover
within five minutes of applying the sealer.
NOTE:Engine front cover can be distorted during
removal. NOTE:Install a new engine front cover.
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Using the special tool and a spatula, separate Apply a 3 mm diameter bead of sealer to the
the engine front cover from the engine. engine front cover.
• Insert the special tool between the engine
front cover and the engine, slide the special
tool counterclockwise, make enough room
for the spatula and return the special tool to
the original position.
• Slide the spatula counterclockwise around
the engine front cover, cutting the silicone
gasket.
• Remove and discard the engine front cover.
ELE0005774
5. Using the special tool, install the engine front

cover.
303-428
ELE0005771
Installation
1. Clean the mating faces of the engine and the
engine front cover. 303-682
ELE0015462
2. Install two M10 x 60 mm locating studs to
the cylinder block to aid installation of the
engine front cover gasket. 6. Remove the locating studs.
7.
CAUTION:Install new M6 x 16 mm engine
front cover bolts, if necessary.
2007.50 Transit 11/2006 G552706en

IN-VEHICLE REPAIR
Install the engine front cover nuts and bolts. 10. Install the accessory drive belt idler pulley
and the cooling fan pulley.
• 2 nuts.
• 20 bolts.
53 Nm
14 Nm
10 Nm
53 Nm
ELE0015439
TIE0020782
11. Attach the thermostat housing support

8. Install the engine front cover nuts and bolts. bracket to the cylinder head and connect
the radiator upper hose to the thermostat
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• 2 nuts. housing.
• 20 bolts.
23 Nm
14 Nm 6 Nm
10 Nm
23 Nm
ELE0015437
TIE0020782
12. NOTE:Install a new coolant outlet connector

9. NOTE:Install a new crankshaft front oil seal.
O-ring seal and a new degas hose.
NOTE:A new crankshaft front oil seal is supplied
Connect the coolant outlet and degas
with an alignment sleeve that will be pushed out
connector to the engine.
during installation.
1. Install the bolts.
Using the special tool, install the crankshaft
front oil seal. 2. Connect the hose.
1 22 Nm
303-679 2
ELE0005759
ELE0015450
13. NOTE:Install a new water pump gasket.
2007.50 Transit 11/2006 G552706en

IN-VEHICLE REPAIR
Attach the water pump and brake vacuum 16. Install the starter motor.
pump to the engine (four bolts). For additional information, refer to:Starter
Motor - 2.4L Duratorq-TDCi (Puma) Diesel
(303-06 Starting System, Removal and
Installation).
17. Install the cooling fan motor and shroud.
For additional information, refer to:Cooling
22 Nm Fan Motor and Shroud (303-03 Engine
Cooling, Removal and Installation).
18. Fill and bleed the cooling system. For
additional information, refer to:(303-03
Engine Cooling)
ELE0005757
14. Diesel/2.4L Duratorq-TDCi (Puma) Diesel,
CAUTION:Crankshaft pulley retaining
bolts must only be used three times. Vehicles With: Fuel Fired Booster Heater
(General Procedures),
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NOTE:Stamp the crankshaft pulley retaining bolt Cooling System Draining, Filling and
heads with a center punch to indicate usage. Bleeding - 2.2L Duratorq-TDCi (Puma)
Using the special tool, install the crankshaft Diesel/2.4L Duratorq-TDCi (Puma) Diesel,
pulley. Vehicles Without: Fuel Fired Booster
Heater (General Procedures).
• Stage 1: 45 Nm.
• Stage 2: 90 degrees.
303-1177
E63363
15. Remove the special tool.
303-393
E75705
2007.50 Transit 11/2006 G552706en

IN-VEHICLE REPAIR
Valve Springs
Special Tool(s) 2. Remove the rocker carrier.
Compressor, Valve Spring
303-060 (21-024)
0
x1
21024
Adapter for 303-060

303-060-05 (21-024-05)
E75617
2102405
3. Loosen the valve collets.
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• Position a socket on the valve spring seat
Adapter for 303-060 and gently strike it with a hammer.
303-060-07 (21-024-07)
2102407
Installer, Valve Stem Collets

303-362 (21-156)
ELE0005394
21156
4. Position the appropriate piston at top dead

center (TDC).
5. Using the special tools, remove the valve
Removal collets.
1. Remove the valve cover.
For additional information, refer to:Valve 303-060-05 303-060
Cover (303-01 Engine - 2.4L Duratorq-TDCi
(Puma) Diesel, In-vehicle Repair).
303-060-07
303-362
ELE0005396
6. Remove the valve springs.
2007.50 Transit 11/2006 G552707en

IN-VEHICLE REPAIR
Installation
1. Install the valve springs.
2. Using the special tools, install the valve
collets.
303-060-05 303-060
303-060-07
303-362
ELE0005396
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3. Install the rocker carrier.
• Stage1: 10 Nm
• Stage 2: 30 degrees
0
x1
E75617
4. Install the valve cover.

For additional information, refer to:Valve
2007.50 Transit 11/2006 G552707en

IN-VEHICLE REPAIR
Valve Seals (21 238 0)

Special Tool(s)
Pliers, Valve Stem Oil Seal
303-508 (21-211)
21211
Removal
1. Remove the valve springs.
For additional information, refer toValve
Springsin this section.
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2. Using the special tool, remove the valve
seals.
303-508
ELE0015837
Installation
1. To install reverse the removal procedure.
2007.50 Transit 11/2006 G25489en

IN-VEHICLE REPAIR
Valves (21 215 4)

Special Tool(s) • Position a socket on the valve spring seat
and gently strike it with a hammer.
Compressor, Valve Spring
303-060 (21-024)
21024
Adaptor for 303-060

303-060-05 (21-024-05)
ELE0015706
2102405
3. Using the special tools, remove the valve
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collets.
Adaptor for 303-060
303-060-07 (21-024-07)
303-060
303-362
2102407
303-060-05
Installer, Valve Stem Collets
303-362 (21-156)
303-060-07
ELE0015707
21156
4. Remove the valves springs.
5. Remove the valves.
Removal Installation
1. Remove the cylinder head.
1. Install the valves.
For additional information, refer toCylinder
2. Install the valves springs.
Headin this section.
2. Loosen the valve collets.
2007.50 Transit 11/2006 G25490en

IN-VEHICLE REPAIR
3. Using the special tools, install the valve
collets.
303-060
303-362
303-060-05
303-060-07
ELE0015707
4. Install the cylinder head.

For additional information, refer toCylinder
Headin this section.
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2007.50 Transit 11/2006 G25490en

IN-VEHICLE REPAIR
Camshafts (21 284 0)

Special Tool(s) 5. Detension and lock the timing chain
tensioner.
Timing Tool, Crankshaft TDC
303-675 (21-234) 1. Retract the pawl.
2. Push the lock in.
3. Insert a pin.
303675
3
General Equipment
Three 6 mm drill bits 1
Materials
Name Specification 2
Loctite 510 WSK-M2G348-A7
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ELE0015463
Removal
1. Remove the valve cover. 6. Remove the timing chain tensioner and the
right-hand timing chain guide.
2. Remove the engine front cover.
For additional information, refer to:Engine
Front Cover (303-01 Engine - 2.4L
Duratorq-TDCi (Puma) Diesel, In-vehicle
Repair).
3. Remove the crankshaft position (CKP)
sensor.
For additional information, refer ELE0015445
to:Crankshaft Position (CKP) Sensor - 2.4L
Duratorq-TDCi (Puma) Diesel (303-14 7. Remove the timing chain upper guide.
Electronic Engine Controls, Removal and
Installation).
4. Remove the rocker carrier.
0
x1
TIE0006889
E75617
2007.50 Transit 11/2006 G552708en

IN-VEHICLE REPAIR
8. Remove the camshaft sprockets and the 2. Turn engine to 50 degrees before top dead
timing chain. center (TDC) and insert the special tool
through the CKP sensor hole.
303-675
ELE0012549
VUE0016156
9.
CAUTION:Remove the camshaft carrier
3. Apply a 2.5 mm diameter bead of Loctite 510
bolts in the sequence shown.
to the mating face of the cylinder head.
cardiagn.com
Remove the camshaft carrier.
6 10 11 7
19
18
15
14
25
24
23
22
21
20
17
16
8 9
2 4 12 13 5 3 1 ELE0013422
ELE0012982
4. Install the camshafts.

10. Remove the camshafts.
5. Install the camshaft carrier.
Installation • Tighten the bolts in the sequence shown in

two stages.
1. Clean the mating faces of the camshaft • Stage 1: Tighten bolts 1 through 22 to 23
carrier and the cylinder head. Nm.
2007.50 Transit 11/2006 G552708en

IN-VEHICLE REPAIR
• Stage 2: Tighten bolts 23 through 25 to 10 Install the camshaft sprockets and the timing
Nm. chain.
20 16 15 19
7
8
11
12
1
2
3
4 ELE0015568
5
6 8. Insert 6 mm drill bits through the holes in
9 the camshaft sprockets and tighten the
10
camshaft sprocket retaining bolts finger
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tight.
18 17
24 22 14 13 21 23 25
ELE0013002
6. Install the timing chain tensioner and the

right-hand timing chain guide.
ELE0015453
9. Install the timing chain upper guide.
15 Nm
ELE0015446
7. 15 Nm
CAUTION:The copper links of the timing TIE0006905
chain must align with the timing marks on
the camshaft sprockets.
2007.50 Transit 11/2006 G552708en

IN-VEHICLE REPAIR
10. Loosen the fuel injection pump sprocket 13. Tighten the camshaft sprocket and fuel
retaining bolts. injection pump sprocket retaining bolts.
33 Nm 33 Nm
32 Nm
32 Nm
ELE0013424 ELE0013421
11. 14. Remove the drill bits from the holes in the
CAUTION:The copper link of the timing
camshaft sprockets and fuel injection pump
chain must align with the timing mark on
sprocket.
the fuel injection pump sprocket.
cardiagn.com
Insert a 6 mm drill bit through the hole in the
fuel injection pump sprocket and tighten the
fuel injection pump sprocket retaining bolts
finger tight.
ELE0015447
15. Remove the special tool from the CKP

sensor hole.
ELE0015454
12. NOTE:Make sure the timing chain tensioner 303-675

is completely released.
Unlock the timing chain tensioner by
removing the pin.
VUE0016156
16. Install the rocker carrier.

• Stage 1: 10 Nm
ELE0015448
2007.50 Transit 11/2006 G552708en

IN-VEHICLE REPAIR
• Stage 2: 30 degrees 19. Check the timing by inserting the special
tool in the CKP sensor hole.
0
x1
303-675
E75617
VUE0016156
17. Rotate the crankshaft clockwise two

revolutions. 20. Remove the special tool from the CKP
sensor hole.
21. Remove the drill bits from the holes in the
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sprocket.
22. Install the CKP sensor.
For additional information, refer
to:Crankshaft Position (CKP) Sensor -
2.4L Duratorq-TDCi (Puma) Diesel (303-14
Electronic Engine Controls, Removal and
Installation).
ELE0013442
23. Install the engine front cover.
For additional information, refer to:Engine
18. Check the camshaft timing by inserting the
Front Cover (303-01 Engine - 2.4L
6 mm drill bits through the holes in the
Repair).
sprocket.
24. Install the valve cover.
Cover (303-01 Engine - 2.4L
Repair).
ELE0015447
2007.50 Transit 11/2006 G552708en

IN-VEHICLE REPAIR
Exhaust Manifold (21 187 0)

Removal • Discard the studs.
1. Remove the turbocharger. For additional

information, refer to:(303-04 Fuel Charging
and Controls - Turbocharger)
Turbocharger - 2.4L Duratorq-TDCi (Puma)
Diesel (100 PS/115 PS) (Removal and
Installation),
Diesel (140 PS) (Removal and Installation).
2. Remove the oil level indicator and tube.
• Discard the O-ring seal. ELE0015460
Installation
cardiagn.com
1. NOTE:Install new exhaust manifold studs,
bolts, nuts, gaskets and O-ring seals.
Install the exhaust manifold studs.
VUE0014637
3. Remove the exhaust manifold.
20 Nm
2
3 x2 ELE0015570
x6
2. Install the exhaust manifold.
1 40 Nm 2
3 40 Nm x2
E74239
4. Remove the exhaust manifold studs. x6
20 Nm 1
E75159
2007.50 Transit 11/2006 G552709en

IN-VEHICLE REPAIR
3. Install the oil level indicator tube.
23 Nm
VUE0015010
4. Install the turbocharger. For additional

information, refer to:(303-04 Fuel Charging
and Controls - Turbocharger)
cardiagn.com
Diesel (100 PS/115 PS) (Removal and
Installation),
Diesel (140 PS) (Removal and Installation).
2007.50 Transit 11/2006 G552709en

IN-VEHICLE REPAIR
Cylinder Head (21 163 0)

Special Tool(s) 2. Remove the generator.
Dial Indicator Gauge (Metric) For additional information, refer to:Generator
205-069 (15-046) - 2.4L Duratorq-TDCi (Puma) Diesel (414-02
Generator and Regulator, Removal and
Installation).
3. Remove the intake manifold.
15046
For additional information, refer to:Intake
Manifold (303-01 Engine - 2.4L
Holding Fixture, Dial Indicator Duratorq-TDCi (Puma) Diesel, In-vehicle
Gauge Repair).
205-070 (15-022A) 4. Remove the exhaust manifold.
For additional information, refer to:Exhaust
15022A Duratorq-TDCi (Puma) Diesel, In-vehicle
Repair).
cardiagn.com
Remover/Installer, Cooling 5. Remove the exhaust gas recirculation (EGR)
Hose Clamp cooler.
303-397 (24-003) For additional information, refer to:Exhaust
Gas Recirculation (EGR) Cooler - 2.4L
24003
Duratorq-TDCi (Puma) Diesel (303-08
Engine Emission Control, Removal and
Installation).
Holding Fixture, Dial Indicator 6. Remove the camshafts.

Gauge For additional information, refer
303-432 (21-183) to:Camshafts (303-01 Engine - 2.4L
Repair).
21183
7. Using the special tool, disconnect the
coolant expansion tank hose and the radiator
upper hose.
Removal
1. Drain the cooling system. For additional
information, refer to:(303-03 Engine Cooling)
303-397
Vehicles With: Fuel Fired Booster Heater
ELE0005736
2007.50 Transit 11/2006 G552710en

IN-VEHICLE REPAIR
8. Detach the power steering pump from the • Discard the gasket and the bolts.
engine and position it to one side (four
bolts).
1 2
12
11
6
5
16
15
10
9
18
ELE0005743
17
8
9. Detach the generator wiring harness from 7
the engine lifting eye and the power steering 14
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pump and generator mounting bracket.
13
3 4
ELE0012985
Installation
1. Clean the mating faces of the cylinder head
TIE0006875 and the cylinder block with Loctite 7070.
2. Check the cylinder head for distortion.
10. Remove the power steering pump and
generator mounting bracket. For additional information, refer
to:Specifications (303-01 Engine - 2.4L
Duratorq-TDCi (Puma) Diesel,
Specifications).
3. NOTE:Measure the piston protrusion of each
cylinder at top dead center (TDC).
ELE0005745
11.
CAUTION:Remove the cylinder head
bolts in the sequence shown.
Remove the cylinder head.
2007.50 Transit 11/2006 G552710en

IN-VEHICLE REPAIR
Measure the distance between the piston • Stage 5: Tighten bolts 1 through 10 to 40
crown and the cylinder block at the points Nm.
indicated. • Stage 6: Tighten bolts 11 through 18 to 20
Nm.
• Stage 7: Tighten bolts 1 through 10 to 180
degrees.
degrees.
TIE0035365
4. NOTE:The largest measurement determines

the choice of the cylinder head gasket.
cardiagn.com
Using the special tools, measure the piston
protrusion.
205-070 205-069
303-432
TIE0035364
TIE0017814
5. Determine the cylinder head gasket.

7. Install the power steering pump and
For additional information, refer generator mounting bracket.
to:Specifications (303-01 Engine - 2.4L
Duratorq-TDCi (Puma) Diesel,
Specifications).
6.
CAUTION:Install new cylinder head bolts.
Install the cylinder head.
• Tighten the bolts in the sequence shown in
eight stages.
Nm.
22 Nm
• Stage 2: Tighten bolts 11 through 18 to 5 ELE0005760
Nm.
• Stage 3: Tighten bolts 1 through 10 to 20 Nm
Nm.
2007.50 Transit 11/2006 G552710en

IN-VEHICLE REPAIR
8. Attach the power steering pump to the 13. Install the intake manifold.
engine (four bolts).
For additional information, refer to:Intake
Repair).
14. Install the generator.
23 Nm to:Generator - 2.4L Duratorq-TDCi (Puma)
Diesel (414-02 Generator and Regulator,
Removal and Installation).
15. Fill and bleed the cooling system. For
additional information, refer to:(303-03
ELE0005762 Engine Cooling)
9. Using the special tool, connect the coolant Bleeding - 2.2L Duratorq-TDCi (Puma)
expansion tank hose and the radiator upper Diesel/2.4L Duratorq-TDCi (Puma) Diesel,
hose. Vehicles With: Fuel Fired Booster Heater
cardiagn.com
303-397
ELE0005736
10. Install the camshafts.

to:Camshafts (303-01 Engine - 2.4L
Repair).
11. Install the EGR cooler.
Gas Recirculation (EGR) Cooler - 2.4L
Engine Emission Control, Removal and
Installation).
12. Install the exhaust manifold.
Repair).
2007.50 Transit 11/2006 G552710en

IN-VEHICLE REPAIR
Oil Pan (21 154 0)

Special Tool(s) 4. Remove the oil pan retaining bolts (16 bolts).
Seperator, Oil Pan
303-428 (21-179)
21179
Materials
Name Specification
Three M6 x 20 mm ELE0012537
locating studs
Silicon sealer WSE-M4G323-A4 5.
CAUTION:Do not distort the oil pan.
cardiagn.com
Engine oil WSS-M2C913-A1 Using the special tool, detach the oil pan
from the cylinder block.
Removal • Slide the special tool around the profile of
the oil pan.
1. Raise and support the vehicle. For additional
information, refer to Section 100-02 [Jacking
and Lifting].
2. Drain the engine oil.
3. NOTE:Inspect the oil pan drain plug seal for
damage. Install a new drain plug and seal if
required. 303-428
Install the drain plug.
ELE0013423
6. Remove the oil pump pickup tube.

23 Nm
TIE0017569
ELE0012991
7. Remove the oil pan.
2007.50 Transit 11/2006 G25494en

IN-VEHICLE REPAIR
Installation • Remove the locating studs.
1. Install three M6 x 20 mm locating studs to

the cylinder block to aid installation of the
oil pan.
2.
CAUTION:Install the oil pan within five
minutes of applying the sealer.
Apply a 3 mm diameter bead of sealer to the
mating face of the oil pan.
ELE0012537
6. Tighten the oil pan retaining bolts.

two stages.
• Stage 1: Tighten bolts 1 through 16 to 7 Nm.
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Nm.
ELE0013450
3. Position the oil pan above the engine 15 13 16

crossmember.
4. Install the oil pump pickup tube.
14
12 6
7
5
2
1
10 Nm
3
4
ELE0015708
10
11
5. NOTE:Do not fully tighten the oil pan
retaining bolts at this stage.
Install the oil pan (16 bolts). 9 8
ELE0015465
7. Lower the vehicle.

8. Fill the engine with oil.
2007.50 Transit 11/2006 G25494en

IN-VEHICLE REPAIR
Oil Pump (21 714 0)

Special Tool(s) 4. Remove the oil pump retaining bolts.
Aligner, Oil Pump
303-705 (21-256)
303705
Removal
1. Remove the oil pan. ELE0021736
For additional information, refer to:Oil Pan

(303-01 Engine - 2.4L Duratorq-TDCi (Puma) 5. NOTE:On engines equipped with hydraulic
Diesel, In-vehicle Repair) chain tensioner, engine oil will be expelled
cardiagn.com
/ Oil Pan (303-01 Engine - 2.2L Duratorq-TDCi when the chain is pulled down.
(Puma) Diesel, In-vehicle Repair). Remove the oil pump.
2. NOTE:The profile of the special tool must be • Pull down on the oil pump chain to release
in contact with the oil pump sprocket. the chain from the sprocket.
Install the special tool to the engine block
and finger tighten the two bolts.
• Push the special tool against the oil pump
sprocket.
• Tighten the two bolts.
303-705
ELE0021554
Installation
1. NOTE:Do not fully tighten the oil pump
ELE0021734 retaining bolts at this stage.
Install the oil pump.
3. Remove the oil pick up pipe.
• Install the chain onto the oil pump sprocket.
2007.50 Transit 11/2006 G25513en

IN-VEHICLE REPAIR
• Install the oil pump retaining bolts finger tight. 5. Install the oil pan.
For additional information, refer to:Oil Pan
(303-01 Engine - 2.4L Duratorq-TDCi (Puma)
Diesel, In-vehicle Repair)
/ Oil Pan (303-01 Engine - 2.2L Duratorq-TDCi
ELE0021741
2. NOTE:The profile of the special tool must be

in contact with the oil pump sprocket.
Push the oil pump forward so that the
sprocket is in contact with the special tool.
cardiagn.com
• Tighten the oil pump retaining bolts.
303-705
10 Nm
ELE0021737
3. Remove the special tool.

4. Install the oil pick up pipe.
10 Nm
ELE0021738
2007.50 Transit 11/2006 G25513en

IN-VEHICLE REPAIR
Crankshaft Rear Seal (21 468 4)

Materials Installation
Name Specification 1.
CAUTION:A new crankshaft rear seal
Silicone Sealant WSE-M4G323-A4
carrier is supplied with an alignment sleeve
that must not be removed until the
Removal crankshaft rear seal is fully installed. Failure
to follow this instruction may result in
1. Remove the clutch disc and pressure plate. damage to the vehicle.
For additional information, refer to: NOTE:Clean the area on the cylinder block before
Clutch Disc and Pressure Plate (308-01 installing a new crankshaft rear seal carrier.
Clutch - Vehicles With: MT-75, Removal
Check the two foam pads are located as
and Installation),
shown on the ladder frame gasket.
Clutch Disc and Pressure Plate (308-01
Clutch - Vehicles With: MT82, Removal and
Installation).
cardiagn.com
2. Remove the flywheel.
• Discard the bolts.
E58864
2. CAUTIONS:
Install the new crankshaft rear seal carrier
TIE0012992 within five minutes of applying the
recommended sealant. Failure to follow this
instruction may result in damage to the
3. Remove the crankshaft rear oil seal carrier. vehicle.
• Discard the carrier.
Do not add any more than the specified
quantity of sealant or add the sealant
anywhere other than the area shown.
TIE0012994
2007.50 Transit 11/2006 G837084en

IN-VEHICLE REPAIR
If the foam pads are not present on • Stage 3: Tighten bolts 1 through 8 to 48
inspection, fill the square areas shown with degrees.
75% of sealant.
5 3 1
7 6
2 8
4
TIE0013727
E58886
7. Install the clutch disc and pressure plate.
3. NOTE:Install a new crankshaft rear oil seal For additional information, refer to:
carrier and crankshaft rear oil seal carrier Clutch Disc and Pressure Plate (308-01
cardiagn.com
retaining bolts. Clutch - Vehicles With: MT-75, Removal
NOTE:A new crankshaft rear oil seal carrier is and Installation),
supplied with an alignment sleeve that must be Clutch Disc and Pressure Plate (308-01
removed following installation. Clutch - Vehicles With: MT82, Removal and
Installation).
NOTE:Do not fully tighten the crankshaft rear oil
seal carrier retaining bolts at this stage.
Install the crankshaft rear oil seal carrier.
4. Tighten the crankshaft rear oil seal carrier
retaining bolts.
• Tighten the bolts in the sequence shown.
3 10 Nm 1
5
9
7 8
2 4
TIE0012542
5. Remove the crankshaft rear oil seal carrier

alignment sleeve.
6. NOTE:Install new flywheel bolts.
Install the flywheel.
three stages.
2007.50 Transit 11/2006 G837084en

REMOVAL
Engine
Removal
2. Disconnect the battery ground cable.
Special Tool(s)
Refer to:Battery Disconnect (414-01 Battery,
Lifting Bracket, Engine
Mounting and Cables, General Procedures).
303-122
3. Within the datalogger function of WDS, check
that the fuel pressure has dropped to zero and
that the fuel temperature has either reached
ambient temperature or is below 30ºC whichever
21068A
is the greater.
General Equipment General Equipment: Worldwide Diagnostic

System (WDS)
Worldwide Diagnostic System (WDS)
4.
Coolant hose clamp remover/installer
Vehicle/axle stands
cardiagn.com
Trolley jack
Hydraulic jib crane
1. Remove the following items:
1. Air cleaner
Refer to:Air Cleaner - 2.3L Duratec-HE
(MI4)/2.4L Duratorq-TDCi (Puma) Diesel
(303-12 Intake Air Distribution and Filtering,
Removal and Installation). E66889
2. Front Bumber
Refer to:Front Bumper (501-19 Bumpers, 5.
3. Condenser Core
Refer to:Condenser Core (412-03 Air
Conditioning, Removal and Installation).
4. Radiator
Refer to:Radiator (303-03 Engine Cooling,
5. Power Steering Pump
Refer to:Power Steering Pump - 2.4L
Duratorq-TDCi (Puma) Diesel (211-02 E69992
Power Steering, Removal and Installation).
6. Accessory Drive Belt
Refer to:Accessory Drive Belt - 2.4L
Accessory Drive, Removal and Installation).
7. Catalytic Converter
Refer to:Catalytic Converter - 2.4L
Exhaust System, Removal and Installation).
2007.50 Transit 11/2006 G832469en

REMOVAL
6. 9.
E71857 E58489
7. General Equipment: Coolant hose clamp 10.

remover/installer
cardiagn.com
E71949
E69170
8. General Equipment: Coolant hose clamp

remover/installer
E64707
2007.50 Transit 11/2006 G832469en

REMOVAL
11. 13. General Equipment: Vehicle/axle stands
E71953
14. General Equipment: Trolley jack
cardiagn.com
E73836
E72140
12.
15.
x3
1
E71951
E72118
2007.50 Transit 11/2006 G832469en

REMOVAL
16. 20. Install the special tool.
Special Tool(s): 303-122
General Equipment: Hydraulic jib crane
303-122
E58910
17. E68699
21.
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2
1
E71954
18. E68700
22.
x4
E72117
19. Push the vehicle back. E73235
2007.50 Transit 11/2006 G832469en

REMOVAL
23. 26.
x4
E73236 E72120
24.
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E68701
25.
x4
E72119
2007.50 Transit 11/2006 G832469en

DISASSEMBLY
Engine
Disassembly Special Tool(s)
Special Tool(s) Remover/Installer, Engine
Mounting Stand Front Cover Inspection Plate
303-435 303-679
303679
21187
Locking Tool, Fuel Injection

Mounting Bracket for 303-435 Pump Sprocket
303-435-06 303-1151
E56412
cardiagn.com
21031B
Remover, Crankshaft Timing

Mounting Plate for Pulley
303-435-06 303-249
303-435-11B
21132
E68386
1. Install the special tools.

303-122 Special Tool(s): 303-435, 303-435-06,
303-435-11B
303-435-11B
21068A
Socket, Cylinder Head

Temperature Sensor
303-680
303-435-06 303-435
303680 E76036
Locking Tool, Flywheel

303-254
21135
2007.50 Transit 11/2006 G832470en

DISASSEMBLY
2. Remove the special tool. 5. Special Tool(s): 303-680
303-122
303-680
x2
x2
E75819
E68699
6.
3.
x4
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x3
E75823
E73646
7.
4.
x7
x4
x5
E75824
E75818
2007.50 Transit 11/2006 G832470en

DISASSEMBLY
8. 11.
x9
2
x1
x2
E75825 E75821
9. CAUTIONS: 12.
Make sure that the fuel line remains in
contact at both ends until both unions
nuts have been unscrewed and the area
cardiagn.com
around the joints thoroughly cleaned.
Make sure that the high-pressure fuel
supply line remains in contact with both
the fuel pump and the fuel rail until both
unions have been detached and
cleaned.
Make sure that all openings are sealed. x2
Use new blanking caps. E75851
Vacuum foreign material from the high-pressure

fuel supply line, the fuel pump and the fuel rail. 13.
Refer to:Fuel Injection Component Cleaning
(303-04 Fuel Charging and Controls - 2.2L
Duratorq-TDCi (Puma) Diesel, General
Procedures).
10. Discard the high-pressure fuel supply lines.
x2
x4
x5
E75852
x4
E75826
2007.50 Transit 11/2006 G832470en

DISASSEMBLY
14. 17. Special Tool(s): 303-679
303-679
x2
x6
E75853 E70896
15. Special Tool(s): 303-254 18.
3 1 1
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6
5
4 2
303-254 2
E65889 E73829
16. Special Tool(s): 303-679 19. Using the special tool, support the fuel pump
sprocket.
303-679
303-1151
E75951
E73830
2007.50 Transit 11/2006 G832470en

DISASSEMBLY
20. 23.
x3
x3
E73832 E75822
21. While supporting the fuel pump, operate the 24.

special tool.
cardiagn.com
303-249
x20
x2
E75620
E73831 25.
22. 24 18 10 6 4 2 12 20
22 8
14 16
13 15
21
7
23
17 9 5 3 1 11 19
E75949
E73833
2007.50 Transit 11/2006 G832470en

DISASSEMBLY
26. 29.
x2 x3
x3
x3
x2
x4
x2
E75950 E75955
27. 30.
3 15 7 17 5 13 1 x5
cardiagn.com
11 9
12 10
4 16 8 18 6 14 2
E75952 E75956
28. 31.
4 11 15 16 20 21 17 12
1
9 5
8
x4
6
3
10
7
14 19 22 18 13 2
E75954 E75953
2007.50 Transit 11/2006 G832470en

DISASSEMBLY
32.
E73644
33.
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E76386
34.
E73645
2007.50 Transit 11/2006 G832470en

Cylinder Head (21 165 6)

Special Tool(s) 3. Remove the engine front lifting eye.
Socket Wrench, Cylinder
Head Temperature (CHT)
Sensor
303-680 (21-239)
303680
Disassembly 23 Nm x2
1. Disconnect the glow plug electrical E75704

connectors.
4. Remove the engine rear lifting eye.
cardiagn.com
12 Nm
ELE0015704 23 Nm x2
E75758
2. Remove the glow plugs.
5. Using the special tool, remove the cylinder
head temperature (CHT) sensor.
• Discard the CHT sensor.
303-680
12 Nm
ELE0015703
ELE0015700
Assembly
1. To assemble, reverse the disassembly
procedure.
2007.50 Transit 11/2006 G837085en

2.
CAUTION:Install a new cylinder head
temperature (CHT) sensor.
303-680
10 Nm
ELE0015701
cardiagn.com
2007.50 Transit 11/2006 G837085en

ASSEMBLY
Engine
Assembly Special Tool(s)
Special Tool(s) Mounting Stand
Bolt, Cylinder Liner 303-435
303-431
21187
21182
Mounting Bracket for 303-435

Dial Indicator Gauge (Metric) 303-435-06
205-069
21031B
15046
cardiagn.com
Mounting Plate for
Holding Fixture, Dial Indicator 303-435-06
Gauge 303-435-11B
205-044
E68386
15008
General Equipment
Remover/Installer, Engine Piston ring compressor
Front Cover Inspection Plate
303-679 Round-ended steel rule
1. Torque:
• Stage1: 45 Nm
303679
• Stage2: 80 Nm
• Stage3: 105°
Socket, Cylinder Head
Temperature Sensor
303-680
303680

303-122
E73645
21068A
2007.50 Transit 11/2006 G832471en

ASSEMBLY
2. The piston ring gaps must be distributed evenly 5. The ladder frame and the cylinder block must
around the circumference of the piston. This be aligned so that the rear clearance does not
also applies to the oil control ring elements. exceed 0.01 mm overlap to 0.2 mm gap.
Align the piston ring gaps at 120° to each other. General Equipment: Round-ended steel rule
General Equipment: Piston ring compressor
E76155
E76386
6. Torque: 23 Nm
cardiagn.com
3. Torque:
• Stage1: 30 Nm 19 12 8 11 22
• Stage2: 100° 7 3 2 6
14
18
15
16 9 4 1 5 10
13 17
20
21
E73643
7. NOTE: Only tighten the bolts finger tight at this

E73644 stage.
4. The ladder frame and the cylinder block must

be aligned so that the side clearance does not
exceed 0.05 mm overlap to 0.05 mm gap.
x4
E75954
303-431
E76169
2007.50 Transit 11/2006 G832471en

ASSEMBLY
8. Take a reference measurement from the front 11.
face of the crankshaft sprocket.
Special Tool(s): 205-069, 205-044
205-069
E76144
205-044
E76358 12. Torque:

• Stage1: 7 Nm
• Stage2: 14 Nm
9. Take measurements at two different points on
the oil pump sprocket and align the oil pump
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sprocket.
Special Tool(s): 205-069, 205-044
E73646
205-044
205-069 13. NOTE:New crankshaft rear seal carriers are

supplied with an alignment sleeve which must
E76359
be removed after installation.
10. Torque: 10 Nm Torque: 10 Nm
4 2
7 6
x4
1 3
5 8
E76152
E75954
2007.50 Transit 11/2006 G832471en

ASSEMBLY
14. 17. Torque:
• 1 33 Nm
• 2 33 Nm
• 3 32 Nm
• 4 15 Nm
• 5 15 Nm
• 6 15 Nm
• 7 15 Nm
x2 4
1 2
x3
x3
5
x2
E76153
7 x4 3
15. Torque:
•
• Stage1: 20 Nm
x2
• Stage2: 40 Nm 2
• Stage3: 180° 6
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E76433
•
• Stage1: 10 Nm
• Stage2: 20 Nm 18. Torque:
• Stage3: 180° • Bolts 1 to 22 23 Nm
• Bolts 23 to 24 10 Nm
3 15 7 17 5 13 1
24 18 10 6 4 2 12 20
11 9
22 8
14 16
12 10 13 15
21
7
4 16 8 18 6 14 2 23
E75952 17 9 5 3 1 11 19
E75949
16. Special Tool(s): 303-679

19. Torque: 22 Nm
x5
303-679
E75951
E75956
2007.50 Transit 11/2006 G832471en

ASSEMBLY
20. Torque: 20 Nm 23. Torque:
• 1 23 Nm
x3 • 2 23 Nm
• 3 10 Nm
3
1
E75955
2
21. Torque: x2
E76435
• 1 40 Nm
• 2 23 Nm
• 3 23 Nm 24. Torque:
• Stage1: 6 Nm
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1 1 • Stage2: 23 Nm
x2
x6
E76434
22. Torque: 20 Nm E66086
25. 1. NOTE:Make sure that a new component is

installed.
Torque: 10 Nm
2. Torque: 10 Nm
x2
1 1
E75852
x4
2
x10
E75602
2007.50 Transit 11/2006 G832471en

ASSEMBLY
26. Using a socket (or similar), press the new fuel 28. Install new fuel injector and fuel rail
injector copper seals onto the fuel injectors high-pressure fuel supply lines.
making sure that the copper seals are pushed Torque:
fully home to prevent uneven clamping. • 1 6 Nm
• 2 3 Nm
• 3 35 Nm
• 4 35 Nm
• 5 35 Nm
• 6 10 Nm
5 x4
6
4 x5
E65265 x4
2
27. CAUTION:Make sure that new bolts are
installed.
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3
Torque:
E76436
• Stage1: 6 Nm
• Stage2: 180°
29. NOTE:Only tighten the bolts finger tight at this
stage.
x9
E65264
E75825
30. Torque:
• 1 10 Nm
• 2 23 Nm
x7 1
2 x5
E76437
2007.50 Transit 11/2006 G832471en

ASSEMBLY
31. Torque: 34. Special Tool(s): 303-680
• 1 23 Nm Torque:
• 2 25 Nm • 1 10 Nm
• 2 23 Nm
• 3 23 Nm
1 x4
303-680 1
x2 2
x3 2
E76438
3 x2
32. 1. Torque: 48 Nm E76440
2. Torque:
35. Torque: 10 Nm
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• Stage1: 45 Nm
• Stage2: 90°
3. Torque: 48 Nm
x4
x3
3
1
E75818
x3
2
E76439 36. Special Tool(s): 303-122
33. Torque: 10 Nm 303-122
x9
E68699
E75825
2007.50 Transit 11/2006 G832471en

ASSEMBLY
37. Special Tool(s): 303-435, 303-435-06,
303-435-11B
303-435-11B
303-435-06 303-435
E76036
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2007.50 Transit 11/2006 G832471en

INSTALLATION
Engine
Installation 3. CAUTION:Make sure that the
Special Tool(s) transmission is installed straight in
relation to the engine to prevent damage
to the pilot bearing.
303-122
Apply a thin film of grease to the input shaft
guide sleeve.
Material: High-Temperature Grease
Torque: 40 Nm
21068A
Materials
Name Specification
High-Temperature ESD-M1C220-A
Grease
General Equipment
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Vehicle/axle stands
Hydraulic jib crane
E68701
Trolley jack
Coolant hose clamp remover/installer 4. Torque: 40 Nm
1. Torque: 62 Nm
x4
E68700
E72120
5.
2. Torque: 62 Nm
x4
E73236
E72119
2007.50 Transit 11/2006 G832472en

INSTALLATION
6. Torque: 40 Nm 9. Remove the special tool.
303-122
E73235
E68699
7. Lower the hydraulic jib crane and support the
engine crossmember on suitable axle stands 10. Push the vehicle forward until the engine and
on both sides. transmission assembly is in place of the engine
General Equipment: Vehicle/axle stands compartment.
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General Equipment: Hydraulic jib crane 11. • On both sides.
Torque:
• 1 70 Nm
• 2 40 Nm
2
1
E71953
8. General Equipment: Trolley jack

E71954
12. Torque: 70 Nm
E72140
E58910
2007.50 Transit 11/2006 G832472en

INSTALLATION
13. Torque: 48 Nm 17.
x4
E72117
14. Raise and support the vehicle.

Refer to:Jacking (100-02 Jacking and Lifting,
Description and Operation).
Refer to:Lifting (100-02 Jacking and Lifting,
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Description and Operation).
15. Torque:
• 1 40 Nm
• 2 55 Nm
2 E73836
18. Torque: 10 Nm
E72118
16. CAUTION:Make sure that new bolts are

installed.
Torque: 115 Nm
E71949
x3
E71951
2007.50 Transit 11/2006 G832472en

INSTALLATION
19. 22.
E58489 E71857
20. General Equipment: Coolant hose clamp 23.

remover/installer
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E69992
E64707
24.
21. General Equipment: Coolant hose clamp
remover/installer
E66889
E69170
25. Connect the battery ground cable.
Refer to:Battery Disconnect (414-01 Battery,
Mounting and Cables, General Procedures).
2007.50 Transit 11/2006 G832472en

INSTALLATION
26. Install the following items:
1. Catalytic Converter
Refer to:Catalytic Converter - 2.4L
Exhaust System, Removal and Installation).
2. Accessory Drive Belt
Refer to:Accessory Drive Belt - 2.4L
Accessory Drive, Removal and Installation).
3. Power Steering Pump
Refer to:Power Steering Pump - 2.4L
Power Steering, Removal and Installation).
4. Radiator
Refer to:Radiator (303-03 Engine Cooling,
5. Condenser Core
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Refer to:Condenser Core (412-03 Air
Conditioning, Removal and Installation).
6. Front Bumper
Refer to:Front Bumper (501-19 Bumpers,
7. Air Cleaner
Refer to:Air Cleaner - 2.3L Duratec-HE
(MI4)/2.4L Duratorq-TDCi (Puma) Diesel
(303-12 Intake Air Distribution and Filtering,
2007.50 Transit 11/2006 G832472en

303-01A-Engine - 2.4L Duratorq-Tdci (Puma) Diesel 303-01A

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303-01A-Engine - 2.4L Duratorq-Tdci (Puma) Diesel 303-01A

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303-01A-1 Engine — 2.

4L Duratorq-TDCi (Puma) Diesel 303-01A-1

SECTION 303-01A Engine — 2.4L Duratorq-TDCi

DESCRIPTION AND OPERATION

DIAGNOSIS AND TESTING

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Engine Data — 140 PS

2007.50 Transit 11/2006 G552703en

Cylinder Block Dimensions

2007.50 Transit 11/2006 G552703en

Piston Pin Dimensions 100 PS

Cylinder Head Dimensions

2007.50 Transit 11/2006 G552703en

Lubricants, Fluids, Sealers and Adhesives

2007.50 Transit 11/2006 G552703en

Engine identification code

Engine emission control

2007.50 Transit 11/2006 G552704en

Compression ratio 17.5:1 Fuel Diesel

Item Description Item Description

B Engine speed (rpm) 3 Torque curve for 85 kW (115 PS) engine

C Power output (kW) 4 Power curve for 85 kW (115 PS) engine

1 Torque curve for 103 kW (140 PS) engine

2007.50 Transit 11/2006 G552704en

Oil level/temperature sensor (140 PS version only)

2007.50 Transit 11/2006 G552704en

2007.50 Transit 11/2006 G552704en

2007.50 Transit 11/2006 G17645en

Intake Manifold (21 183 0)

3. Remove the accessory drive belt shield x2

4. Detach the fuel charging wiring harness and

2007.50 Transit 11/2006 G552648en

Valve Cover (21 141 0)

WARNING:Do not smoke or carry lighted

3. Remove the valve cover.

2007.50 Transit 11/2006 G552705en

Crankshaft Front Seal (21 467 0)

2007.50 Transit 11/2006 G25485en

3. Lower the vehicle.

2007.50 Transit 11/2006 G25485en

Engine Front Cover (21 148 0)

Holding Wrench, Crankshaft

General Equipment 5. Detach the water pump and the brake

2007.50 Transit 11/2006 G552706en

10. Using the special tool, remove the

2 11. Remove the engine front cover nuts and

2007.50 Transit 11/2006 G552706en

12. NOTE:Lubricate the spatula with clean 4.

5. Using the special tool, install the engine front

2007.50 Transit 11/2006 G552706en

11. Attach the thermostat housing support

12. NOTE:Install a new coolant outlet connector

13. NOTE:Install a new water pump gasket.

2007.50 Transit 11/2006 G552706en

15. Remove the special tool.

2007.50 Transit 11/2006 G552706en

Adapter for 303-060

Installer, Valve Stem Collets

4. Position the appropriate piston at top dead

6. Remove the valve springs.

2007.50 Transit 11/2006 G552707en

4. Install the valve cover.

2007.50 Transit 11/2006 G552707en