TRANSIT

General Specifications Transit 1995 (08/1994-07/2000)
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Specifications
Engine Data
General
Engine management EEC V / SFI
Emission standard, vehicles up to 2,8 t 96 EEC
Emission standard, LDT (light commercial
95 EEC
vehicles)
Emission standard, EFTA countries A14
Identification code, vehicles up to 2,8 t NSG
Identification code, LDT (light commercial
NSF
vehicles)
Firing order 1‐3‐4‐2
Bore mm 86,0
Stroke mm 86,0
Cubic Capacity cm3 1998
Compression ratio 9,8:1
Power output (EEC) kW 84
Power output (EEC) (PS) 114
Power output (EEC) at rev/min 5000
Torque (EEC) Nm 170
Torque (EEC) at rev/min 2700
Idle speed rev/min 850 ± 50
Max. permissible engine speed Continuous rev/min 5950
Intermittent
Max. permissible engine speed 6175
rev/min
Spark plugs AGPR12P
Dimensions
Cylinder block Dimensions (mm)
Cast mark 20
Cylinder bore Ø
Standard class 1 mm 86,000 ‐ 86,010
Standard class 2 mm 86,010 ‐ 86,020
Oversize 0,15 mm 86,160 ‐ 86,170
Oversize 0,5 mm 86,500 ‐ 86,510
Number of main bearings 5
Centre main bearing width (excl. thrust half
21,17 ‐ 21,23
rings)
Service standard
Installed main bearing shells, vertical inner Ø 54,983 ‐ 55,020
(yellow)
Standard 55,003 ‐ 55,030
1st undersize 0,05
54,953 ‐ 54,980
mm
2nd undersize 0,25
54,753 ‐ 54,780
mm
3rd undersize 0,50
55,503 ‐ 54,530
mm
Main bearing parent bore Ø Standard 59,287 ‐ 59,300
Oversize 0,40 (black) 59,687 ‐ 59,700
Dimensions
Crankshaft Dimensions (mm)
End float 0,093 ‐ 0,303
Main bearing journal Ø Standard (yellow) 54,98 ‐ 54,99
Standard (red) 54,99 ‐ 55,00
Undersize 0,25
54,73 ‐ 54,75
(green)
Main bearing journal to shell clearance 0.020 ‐ 0,039
Big‐end bearing journal Ø Standard 50,89 ‐ 50,91
Undersize 0,25
50,64 ‐ 50,66
(green)
Thickness of thrust half rings Standard 2,301 ‐ 2,351
Oversize width 0,38
2,491 ‐ 2,541
(yellow)
Width of centre main bearing journal Standard 26,025 ‐ 26,075
Oversize 0,38 (yellow) 26,405 ‐ 26,455
Dimensions
Connecting rods
Bore diameters Big‐end 53,890 ‐ 53,910
Small end 20,589 ‐ 20,609
Fitted big‐end bearing shells
Vertical inner Ø Standard 50,916 ‐ 50,950
1st undersize 0,25
50,666 ‐ 50,700
mm
2nd undersize 0,50
50,416 ‐ 50,150
mm
Big‐end bearing shell clearance 0,006 ‐ 0,060
Big‐end bearing end float 0,09 ‐ 0,31
Dimensions
Camshafts
Number of camshaft bearings 2x5
Single roller chain,
Drive hydraulic chain
tensioner
Dimensions
Camshafts (cont.) Dimensions (mm)
Camshaft end float 0,02 ‐ 0,26
Cam lift Inlet 10,83
Exhaust 10,83
Cam length (between heel and toe) Inlet 52,71 ‐ 52,94
Valve timings Exhaust 52,71 ‐ 52,94
Inlet valve opens
9°
before TDC
Inlet valve closes after
51°
BDC
Exhaust valve opens
51°
before BDC
Exhaust valve closes
9°
after TDC
Camshaft bearing journal diameter 25,96 ‐ 25,98
Bearing inside diameter 26,00 ‐ 26,03
Dimensions
Pistons Dimensions (mm)
Piston Ø (unused) Service standard 85,980 ‐ 86,000
Oversize 0,15 mm 86,130 ‐ 86,150
0,50 mm 86,470 ‐ 86,490
Piston clearance in bore (unused) Production 0,02 ‐ 0,04
Service 0,01 ‐ 0,04
Piston pin length 63,4
Piston pin Ø White 20,622 ‐ 20,625
Red 20,625 ‐ 20,628
Blue 20,628 ‐ 20,631
Clearance in piston (colour match) 0,008 ‐ 0,014
Interference fit in small end bore 0,018 ‐ 0,039
Piston ring gaps (fitted) Top 0,30 ‐ 0,60
Middle 0,50 ‐ 0,80
Oil control ring (three
0,40 ‐ 1,50
part)
Piston ring gaps
should be distributed
evenly around the
piston circumference;
this also applies to the
Ring gap positions
gaps of the
intermediate oil
control rings in
relation to the
expander gap.
Dimensions
Valves Dimensions (mm)
Valve timings DOHC
Valve clearances Hydraulic tappets
Hydraulic tappet Ø 42
Hydraulic tappet clearance in housing 0,025 ‐ 0,080
Valve length Exhaust 108,24 ‐ 108,70
Inlet 108,68 ‐ 109,20
Valve head Ø Inlet 42,5 ‐ 42,7
Exhaust 37,9 ‐ 38,1
Valve stem Ø, standard Inlet 7,025 ‐ 7,043
Exhaust 6,999 ‐ 7,017
Valve stem Ø, oversize 0,2 Inlet 7,225 ‐ 7,043
Valve stem Ø, oversize 0,2 Exhaust 7,199 ‐ 7,217
Valve stem Ø, oversize 0,4 Inlet 7,425 ‐ 7,443
Valve stem Ø, oversize 0,4 Exhaust 7,399 ‐ 7,417
Valve stem clearance in guide Inlet 0,020 ‐ 0,069
Exhaust 0,046 ‐ 0,095
Outer and inner
Colour code Green/Blue
springs
Free valve spring height Outer spring 48,2
‐ Inner spring 49,2
Dimensions
Valves (cont.) Values (N)
Spring force: two valve springs per valve, Valve open, outer
830
inlet and exhaust are identical spring
Inner spring 245
Outer spring and inner
1075
spring
Valve closed, outer
285
spring
Inner spring 115
Outer spring and inner
400
spring
Dimensions
Valves (cont.) Dimensions (mm)
Valve open, outer
Spring height 28,67
spring
Valve open, inner
23,67
spring
Valve closed, outer
39,5
spring
Valve closed, inner
34,5
spring
Valve spring inner Ø Outer spring 24
Inner spring 17,5
Valve spring wire (oval profile) Outer spring 4,1 x 4,95
Valve spring wire Ø Inner spring 2,6
Number of turns Outer spring 6,83
Inner spring 8,82
Dimensions
Lubrication
Oil pressure (SAE 10W/30 and 80° oil
at 875 rev/min 1,60 bar
temperature)
Oil pressure (SAE 10W/30 and 80° oil
at 2000 rev/min 3,10 bar
temperature)
Oil pump, rotor to housing clearance 0,154 ‐ 0,304 mm
Pressure relief valve opens at 3,70 ‐ 4,60 mm
Oil warning light comes on at 0,30 ‐ 0,50 mm
Gap, inner to outer rotor 0,05 ‐ 0,20 mm
Rotor end float at sealing face 0,014 ‐ 0,079 mm
Dimensions
Cylinder head with valve seat inserts*
Cast mark 20
Upper correction angle (production) Inlet/exhaust 70°
Lower correction angle (production) Inlet/exhaust 25°
Valve seat angle 44°30' ‐ 45°
Valve seat width Inlet 1,33 ‐ 2,19 mm
Exhaust 1,68 ‐ 2,54 mm
Valve guide inner bore (inlet/exhaust) Standard 7,063 ‐ 7,094 mm
Camshaft bearing parent bore Ø all 26,00 ‐ 26,03 mm
Allowable distortion ‐ cylinder head mating
0,050
face, across
Allowable distortion ‐ cylinder head mating
0,100 mm
face, lengthways/diagonally
Allowable cylinder head mating face
13,5 mm
roughness (Rz)
Maximum amount of material to be removed
0,2 mm
when machining cylinder head mating face
Cylinder head height (dimension ”a") 16,35 mm
Combustion chamber height (dimension ”b") 147,25 mm
* The valve seat angle locations are explained in the section 'Description and Operation'.
Sump Shims
Range of adjustment Available shims Colour coding
0 ‐ 0,25 mm No adjustment
0,26 ‐ 0,29 mm 0,15 mm Silver
0,30 ‐ 0,44 mm 0,30 mm Pale blue
0,45 ‐ 0,59 mm 0,45 mm Red
0,60 ‐ 0,75 mm 0,60 mm Black
Lubricants, Adhesives and Sealers
Description Ford
Specification
Transmission fluid ESDM‐2C186‐A
Coolant ESD‐M97B‐49A
Sealer, crankshaft front oil seal housing; crankshaft rear main bearing
WSK‐M2G348‐A5
cap, Loctite 518
Sealer for sump, Hylosil 502 WSK‐M4G320‐A
Adhesive sealer for water pump angle connector, Loctite 243 WSK‐M2G349‐A7
Adhesive sealer for temperature gauge sender unit, Loctite 243 WSK‐M2G349‐A7
Lubricant, crankshaft position sensor (CKP) O‐ring SM1C‐115‐A
High temperature grease, clutch release bearing guide sleeve ESD‐M1C‐220‐A
High temperature grease, transmission input shaft splines ESD‐M1C‐220‐A
Hypoid oil ‐ valve stems SQM‐2C9002‐AA
Power steering fluid SQM 2C‐9010‐A
Thread‐locking compound, Loctite 270 SDM‐M4G9107‐A
Spark plug threads, Never Seez ESE‐M1244‐A
Silicone grease A960‐M1C171‐AA
Capacity
Description Litres
Engine oil ‐ first fill with filter (EFL‐90) 5.10
Engine oil ‐ oil change with filter change (EFL‐90) (with air conditioning) 4,50
Engine oil ‐ oil change with filter change (EFL‐90) (without air conditioning) 4,25
Engine oil ‐ oil change without filter change 4,00
Coolant 7,9
Engine Oil
Viscosity / Ambient Designation Specification
Temperature
Recommended engine oil:
SAE 5W30 / below ‐20 to Ford Formula E Economy ACEA A1‐96/B1‐96 and WSS‐
above 40°C Engine Oil M2C912‐A1
Alternative engine oils:
SAE 10W30 / ‐20 to above Ford Super Multigrade Engine ACEA A1‐96/B1‐96 or A2‐
40°C Oil 96/B2‐96 or API/SH/CD EC
SAE 5W40 / below ‐20 to Ford Formula S Synthetic ACEA A3‐96/B3‐96 or
above 40°C Engine Oil API/SH/CD EC
SAE 10W40 / ‐20 to above Ford XR+ High‐performance ACEA A3‐96/B3‐96 or
40°C High‐lubricity Engine Oil API/SH/CD EC
If these engine oils are not available, other engine oils may be used, provided they meet
the API SH/CD EC specification or exceed it.
Torques
General Nm lbf.ft
Radiator grille 11 8
Torques
Exhaust manifold Nm lbf.ft
Front exhaust pipe to exhaust manifold 40 30
Torques
Transmission and driveshaft Nm lbf.ft
Flange bolts ‐ engine to transmission 35 26
Starter motor 35 26
Bracket ‐ front exhaust pipe to transmission mounting 24 18
Front to rear exhaust pipe 38 28
Transmission mounting to transmission 84 62
Transmission crossmember to side members 50 37
Driveshaft to transmission 84 62
Centre bearing ‐ driveshaft to floor pan 33 24
Shift lever to transmission 25 18
Torques
Coolant circuit Nm lbf.ft
Coolant pump 23 17
Radiator mount (upper) 10 7
Torques
Engine mountings Nm lbf.ft
Upper half shell to bracket 50 37
Torques
Oil circuit Nm lbf.ft
Oil drain plug 25 18
Oil pressure switch 27 20
Oil filter mounting 18 13
Oil filter 14 10
Oil cooler mounting 58 43
Oil baffle to cylinder block 19 14
Oil pump 10 7
Oil intake pipe to cylinder block 12 9
Sump to cylinder block (bolts and nuts) 11 8
Sump studs in cylinder block 9 7
Oil pump sprocket 18 13
Torques
Power steering Nm lbf.ft
Power steering fluid pump to bracket 25 18
Power steering pump pulley 25 18
Torques
Cylinder block Nm lbf.ft
Timing chain lower cover 10 7
Oil seal carrier, rear 13 10
Oil seal carrier, front 26 19
Front support bracket to cylinder block 26 19
Crankshaft position sensor (CKP) 4 3
Timing chain guide, M6 12 9
Timing chain guide, M8 26 19
Crankshaft main bearing caps 97 72
Big‐end bearing caps, 1st stage 7 5
Big‐end bearing caps, 2nd stage 16 12
Big‐end bearing caps ‐ 3rd stage 90° 90°
Positive crankcase ventilation (PCV) tube 9 7
Crankshaft belt pulley/vibration damper, 1st stage 52 38
Crankshaft belt pulley/vibration damper, 2nd stage 85° 85°
Flywheel 87 64
Clutch pressure plate to flywheel 24 17
Oil pump chain tensioner arm 12 9
Torques
Cylinder head Nm lbf.ft
Cylinder head to cylinder block, 1st stage 10 7
Cylinder head to cylinder block, 2nd stage 35 26
Cylinder head to cylinder block, 3rd stage 90° 90°
Cylinder head to cylinder block, 4th stage 90° 90°
Cylinder head auxiliary bolts 38 28
Cylinder head cover, 1st stage 3 2
Cylinder head cover, 2nd stage 9 7
Timing chain upper cover 10 7
Camshaft bearing caps 24 17
Camshaft sprockets 59 44
Engine lifting eyes 25 18
Spark plugs 18 13
EI coils 10 7
Description and Operation Transit 1995 (08/1994-07/2000)
Print
Description and Operation

Item Description
1 EI coils
2 Temperature gauge sender unit
Engine coolant temperature (ECT)
3
sensor
4 Throttle position (TP) sensor
5 Idle speed control (ISC) valve
6 Oil pressure switch
7 Crankshaft position (CKP) sensor
8 Central connector
9 Injectors
10 Camshaft position (CMP) sensor
Item Description
1 DPFE sensor
2 Vacuum switching valve
3 Vacuum regulator
Exhaust gas recirculation on the Transit fitted with the DOHC engine is controlled by an
electronic differential pressure feedback EGR (DPFE) system. The differential pressure at a
restriction in the EGR pipe is measured by the DPFE sensor and passed to the EEC V module
as a voltage signal. Depending on this voltage signal, the EEC V module modifies the signal
sent to the electronic vacuum regulator, which then controls the vacuum to the EGR valve.
In this way a precisely measured quantity of exhaust gas passes into the inlet manifold
behind the throttle valve.
The vacuum for the EGR system and the auxiliary air system is taken from a common line.
The vacuum switching valve directs vacuum to the secondary air valve when the engine is
cold, and to the EGR system when the engine is warm. The vacuum switching valve is
controlled by the EEC V module.
Cooling System
Item Description
1 Coolant shut‐off valve
2 Fuel pressure regulator
3 Throttle housing
4 Connection to heater valve system
Evaporative emission control system
5
valve (EVAP)
6 Connection to brake servo
7 Solenoid valve
8 Idle speed control valve (ISC)
Coolant shut‐off valve
 On vehicles with air conditioning the coolant supply to the heater radiator is shut off
when the air conditioning is operating.
 As on the diesel engine, the system operates by vacuum which is passed to the
coolant shut‐off valve by a solenoid valve. The vacuum is supplied by the line to the
brake servo.
 The solenoid is controlled by the EEC V module.
Item Description
Evaporative emission control system
1
valve (EVAP)
2 Vacuum switching valve
3 EGR system vacuum regulator (CVT)
DPFE sensor (differential pressure
4
feedback EGR)
Secondary pump of auxiliary air
5
system
6 Secondary air valve
7 EGR valve
8 Fuel pressure regulator
9 Connection to heater valve system
Auxiliary air system.
 While the engine is warming up, fresh air is introduced into the exhaust manifold to
burn some of the CO and hydrocarbon content of the exhaust gas.
 1 Secondary air injection pump
 2 Secondary air injection valve
Drivebelt routing
Item Description
1 Crankshaft belt pulley
2 Automatic belt tensioner
3 Alternator
4 Coolant pump
5 Power steering pump
6 Alternator for additional heater
7 Air conditioning compressor
Locations of the angles on the valve seat.
1. Locations of the angles on the valve seat.
1. Upper correction angle.
2. Valve seat angle.
3. Lower correction angle.
4. Valve seat width.
Modified parts from MY '95 onwards

2. Connecting rods
• In place of the existing oil splash bore, there is now
a recess on each side of the connecting rod.
• This recess conveys the oil from the bearing shells
to the cylinder bore.
• This provides additional lubrication on the
pressurised side of the cylinder bore.
• New connecting rod bolts marked "KX120" on the
head.
3. Pistons
• The distance from the piston crown to the first
piston ring is reduced to 5 mm.
• The piston rings are phosphated.
• The tolerances have been reduced.
4. Cylinder head gasket.

With effect from the '95 model year, a multi‐
layered steel gasket is used.
5. Inlet manifold gasket.

• Four Viton gaskets arranged in the inlet manifold.
• The four gaskets are not symmetrical.
6. Exhaust manifold gasket

• A two layer steel gasket was introduced from '95
MY.
• Two gaskets per engine.
Gasket for inlet manifold coolant connector.
Different gaskets are used on the DOHC 8V engine, depending on the vehicle in which the
engine is fitted.
Item Description
Gasket with narrow tab for
1 longitudinal engine installation in the
Granada/Scorpio '95 and Transit.
Gasket with broad tab for transverse
2
engine installation.
 The gasket for use on transversely installed engines is closed because the coolant
connection is located at the rear of the cylinder head.
 The gasket identifying tab is visible under the inlet manifold.
Crankshaft Paint Marks
Item Description
Yellow line for standard size (54,99 ‐
54,98) main bearing journals, red line
1
for standard size (55,00 ‐ 54,99)
main bearing journals.
Green line for production undersize
2
(0,25) main bearing journals.
Green line for production undersize
3
(0,25) big‐end bearing journals.
Yellow line for undersize (0,38) centre
4
main bearing journal width.
5 Centre main bearing journal width
Engine ‐ Dismantle and Assemble

Transit 1995 (08/1994-07/2000)
(engine removed) (21 134 8)
Print
Removal and Installation

Special Tools
15‐030AUniversal flange
holding wrench
16‐067Locator for clutch disc
17‐055‐02Depth gauge
21‐023Universal spindle,
mounting stand
21‐031BMounting bracket
21‐036ARemover for pilot

bearing
21‐044AInstaller/locator for
pilot bearing/clutch disc
21‐141Installer for radial oil

seal
21‐146BMounting plate
21‐147Remover for vibration

damper
21‐168Crankshaft
immobilising tool
21‐540Angle gauge
Materials
From: Replacement
Services Limited, 30
Euston Street,
Plastigage
Freemans Industrial
Estate, Leicester, LE2
7ST
Sealer (Loctite 518) WSK‐M2G348‐A5
Sealer (Hylosil 502) WSK‐M4G320‐A
Workshop Equipment
Assembly stand
Proprietary Tools
Dial indicator
Magnetic fixture
Piston ring compressor
Oil filter strap wrench
Micrometer
Feeler gauges
Straightedge
Dismantle
1. Attach the engine to the assembly stand using
Special Tools 21‐146B, 21‐023 and 21‐031B.
2. Standard preparatory measures.
Drain off the engine oil.
3. Lock the crankshaft by inserting the special tool
into the flywheel.
4. Remove the crankshaft pulley/vibration damper.

• Take out the bolt and pull off the pulley/vibration
damper.
• Remove Special Tool 21‐147.
5. Remove the clutch.
6. Loosen the flywheel bolts.

7. Detach Special Tool 21‐168.
8. Remove the flywheel.
9. Remove the positive crankcase ventilation (PCV)
tube.
10. Remove the engine lifting eye.

11. Remove the cylinder head cover (eleven bolts and
four nuts).
12. Remove the timing chain upper cover.
13. Remove the timing chain lower cover with the

integrated oil seal and gasket.
14. Remove the oil pump sprocket and drive chain.
1. Remove the oil pump drive chain tensioner.
2. Remove the oil pump sprocket and drive chain.
15. Set the camshaft sprockets to the marks.
16. Remove the upper chain guide.

The upper chain guide must be renewed when the
engine is reassembled.
17. Remove the camshaft sprockets.
18. Remove the chain tensioner arm.

1. Pull off the circlip using pliers.
2. Pull out the chain tensioner pivot bolt using an M6
bolt.
3. Take the chain tensioner arm out of the housing.
19. Release the chain guide.
20. Remove the timing chain.

• Remove the Woodruff key from the crankshaft.
• Take off the crankshaft sprocket and timing chain.
CAUTION:
Do not re‐use the chain tensioner hydraulic
plunger.
21. Remove the chain tensioner hydraulic plunger
and the timing chain.

22. Remove the camshafts.
• Remove the chain guide bracket with the front
bearing caps.
• Remove the hydraulic tappets and keep them in
order.
CAUTION:
Allow the cylinder head to cool down to at
least 30 °C before undoing the bolts.
NOTE:
Only reuse cylinder head bolts which have
an integral washer (see following
operation).
NOTE:
Release the auxiliary bolts first (x 3).
23. Remove the cylinder head.
24. Cylinder head bolts, distinguishing features.

1. New cylinder head bolts with integral washer.
2. Old cylinder head bolts with separate washer.
25. Remove the coolant pump.
26. Remove the oil pump.
27. Remove the components mounted on the left‐

hand side of the engine.
1. Crankshaft position (CKP) sensor.
2. Oil pressure switch.
3. Oil filter.
If necessary use an oil filter strap wrench.
Only on vehicles with air conditioning.

28. Remove the oil cooler and oil filter.
If necessary use an oil filter strap wrench.
For all vehicles

CAUTION:
Oil sludge and abraded particles must not
get into the engine.
29. Remove the sump downwards.
CAUTION:
Do not damage the cylinder bore.
30. Remove the carbon from the upper edge of the

cylinder bore.
31. Remove the oil intake pipe with strainer and the
oil baffle.
32. Remove the crankshaft front support bracket.

33. Remove the crankshaft rear oil seal carrier.
34. Remove the crankshaft pilot bearing.
35. Remove the pistons.

• Remove the big‐end bearing caps.
• Remove the bearing shells from the big‐end bearing
caps and connecting rods and mark them.
• Press out the pistons with the connecting rods.
36. Remove the crankshaft.

• Remove the main bearing caps.
• Remove the crankshaft.
• Remove the bearing shells and thrust half rings and
keep them in order or mark them for further use.
Reassemble engine
37. Preparations.
• Clean all the mating faces and re‐usable parts
thoroughly and check them for damage.
• When necessary the lower timing chain cover is
renewed together with gasket and integrated oil seal.
38. Measure the diameter of the main and big‐end
bearing journals using a proprietary micrometer
gauge.
• Repeat each measurement at 90°.
• If the measurements are not as specified in the
Technical Data, the crankshaft must be reworked or
renewed.
Measure bearing clearance

39. Fit the crankshaft.
CAUTION:
Do not damage the crankshaft bearings
during installation.
• Lay the main bearing shells with the grooves in the
cylinder block.
• Place the crankshaft in the cylinder block unoiled.
NOTE:
The measurement area must be free of oil.
CAUTION:
The crankshaft must not be turned during the
measuring operation.
40. Measure the crankshaft main bearing clearance.
• Lay the Plastigage across the width of the bearing
journal.
• Fit the bearing cap (see sub‐operation ).
NOTE:
Measure the bearing clearances in sequence
(1‐5).
41. Measure the crankshaft main bearing clearance
(continued).
NOTE:
The main bearing caps are numbered
starting at the timing chain end.
• Put the main bearing cap and its bearing shell in
place, with the arrow pointing towards the timing
chain end, and tighten it down fully.
• Remove the main bearing cap.
(continued).
• Compare the Plastigage thread with the Plastigage
scale.
• The reading shows the main bearing clearance.
• If the reading is outside the specified range for main
bearing clearance (0,011 ‐ 0,048 mm), renew the main
bearing shells and repeat the measurement procedure
from sub‐operation
• If the specified bearing clearance is not achieved,
provided the cylinder block is standard and the
crankshaft is no more than 0,02 mm undersize, the
next largest main bearing shells may be fitted. If this
is done, the measured main bearing clearance must
have been no more than 0,098 mm.
43. Install the crankshaft.
• Coat all main bearing journals, main bearing shells,
all bolts threads and head contact faces with engine
oil.
• Fit the crankshaft.
• Fit the thrust half rings with the copper‐coloured
side facing the crankshaft.
• Apply sealer (WSK‐M2G348‐A5) to the contact faces
and the sides of the rear main bearing cap.
NOTE:
The main bearing caps are numbered
starting from the timing chain end, which is
the end the arrows point towards.
Put the main bearing shells and their matching
bearing caps in place.
NOTE:
Fit the bolts with stud extensions on main
bearing caps three and five.
Tighten the bolts.
44. Check the crankshaft end float.
• Set up a dial indicator.
• Measure the end float as shown.
• Correct the end float as necessary by fitting new
thrust half rings to main bearing no. 3.
45. Check the piston ring gaps.

The values given in Technical Data apply to the
gauge ring used in production. The figures measured
in the cylinder can exceed these by 0,15 mm.
CAUTION:
The upper piston rings are coated with
molybdenum. This coating must not be
damaged.
46. Arrangement of the piston rings.
The piston rings must not be opened out to more
than the cylinder bore diameter plus 1,7 mm.
47. Install the pistons.
• Lubricate the pistons and cylinder bores with engine
oil.
• Distribute the piston ring gaps evenly around the
circumference; this also applies to the elements of the
oil control ring.
NOTE:
Connecting rod numbering starts at the
timing chain end. The arrow on the piston
crown points towards the timing case.
• Compress the piston rings using a proprietary piston
ring compressor.
• Press pistons 1 and 4 into the cylinders using the
handle of a hammer. The big‐end bearing journal must
be at BDC.
• Coat the big‐end bearing shells with engine oil.
• Put the corresponding big‐end bearing shells in the
connecting rod and big‐end bearing cap.
• Fit the big‐end bearing cap.
• Turn the crankshaft 180°, fit pistons 2 and 3.
48. Measure the big‐end bearing clearance.
Measure the big‐end bearing clearance as described
in sub‐operations to , "Measure the crankshaft main
bearing clearance".
49. Install the bearing caps.
Lubricate the bearing shells and bearing journals
with engine oil.
NOTE:
The connecting rods and their associated
bearing caps have the same numbers.
Fit the bearing shells and bearing caps on the
correct connecting rods and tighten them.
50. Install the crankshaft pilot bearing.
51. Remove the rear oil seal from the oil seal carrier.
Install the rear oil seal carrier.

52. Align the oil seal housing.
Fit the new oil seal carrier using a new gasket and
screw in the bolts finger tight.
1. The mating face of the oil seal housing must stand
below the mating face of the cylinder block. The
difference in height must not exceed 0,46 mm.
2. Tighten the bolts.
53. General description of how to fit a radial oil seal

in a special tool with a guide sleeve.
CAUTION:
The radial oil seal must be fitted into the
tool as far as the shoulder.
To fit the oil seal correctly the special tool is laid on
the vice and the seal is pressed in using a hammer
handle.
1. Incorrectly fitted.
2. Correctly fitted.
54. Fit the crankshaft rear oil seal.

Press the oil seal into position using the special tool
and two flywheel bolts.
55. Fit the front support bracket.

NOTE:
After putting the oil seal housing in place
there must be enough sealer protruding at
the side and front.
NOTE:
Protruding sealer must not be removed
before the sump is fitted.
Apply four beads of sealer with a diameter of 3 ‐ 5
mm and a length of 10 mm.
NOTE:
Install the oil baffle so that the oil intake
pipe and oil strainer can be fitted.
56. Install the oil baffle.
57. Install the oil dipstick tube and oil strainer.
Install the sump

58. Apply sealer (WSK‐M4G320‐A) to the flywheel
end of the cylinder block.
NOTE:
The bead of sealer must cover the mating
face gaps.
Apply a bead of sealer 3‐5 mm thick and 10 mm
wide on both sides.
59. Put the sump in position using a new gasket.

• Align the sump as described in sub‐operation
• Tighten the three nuts and the twelve bolts.
• Fit the oil drain plug using a new seal.
60. Align the sump.

• Align the sump so that it stands no more than 0,25
mm short or 0,1 mm proud.
• Measure the difference in height using a steel
straight edge and feeler gauge; make a note of the
measurement.
• Eliminate the difference when installing the engine
by using distance shims (see Technical Data).
CAUTION:
Use new bolts.
NOTE:
It can only be fitted in one position.
61. Fit the flywheel.

• Put the flywheel in position and screw in the bolts.
• Lock the crankshaft by inserting Special Tool 21‐
168 in the flywheel.
• Tighten the flywheel bolts.
62. Centre the clutch disc on the clutch pressure plate.
63. Fit the clutch.

1. Put the clutch pressure plate with centred clutch
disc in place.
2. Tighten the bolts evenly, working diagonally.
3. Detach Special Tools 16‐067 and 21‐168.
64. Dismantle and clean the oil pump.

NOTE:
If the oil pump is worn it is renewed only as
a complete unit.
CAUTION:
Before fitting the new oil pump, fill it with oil
and turn it over by hand.
NOTE:
The dot marks must face outwards.
65. Reassemble the oil pump.

NOTE:
The oil pump passages must not be covered
by the gasket.
66. Fit the oil pump using a new gasket.
67. Install the components fitted on the left‐hand side
of the engine.
• CKP sensor
• Oil pressure switch
• Oil filter
Only on vehicles with air conditioning.

68. Install the oil cooler and oil filter.
For all vehicles

NOTE:
The straight edge must be at least 500 mm
long and 5 mm wide.
69. Check the cylinder head mating face for distortion.
• Allowable distortion at the combustion chamber top
edge: measured across the head: 0,05 mm, diagonally
and along the head: 0,10 mm.
• Lay the straightedge across the head over each
combustion chamber and test each at three positions.
• Lay the straightedge over the combustion chambers
lengthways along the head at three positions and test
at each combustion chamber top edge.
• Lay the straightedge diagonally over the cylinder
head and check at each combustion chamber top
edge.
• If necessary, re‐work the cylinder head as described
in step
70. Instructions for reworking the cylinder head.
NOTE:
Maintain a Peak‐to‐Valley height (Rz) of
0.00135 mm while reworking.
• The cylinder head must not be re‐worked more than
0,20 mm (milling or surface grinding). The minimum
value for "a" is 16,35 mm (see step ) and that for "b"
is 147,25 mm.
NOTE:
Remove any carbon deposits at the
measuring point.
71. Point at which measurement "a" is made in the
combustion chamber.
Install the cylinder head.

72. Position piston number one 25 mm before TDC.
73. Fit the cylinder head.

1. Insert the locating bushes.
2. Lay a new cylinder head gasket in place.
CAUTION:
Do not use old cylinder head bolts which
have separate washers.
74. The new cylinder head bolts with integral washer
may be reused providing that 174.3 mm distance is
not exceeded and the cylinder head bolts show no
signs of damage.
75. Tighten the cylinder head bolts in the sequence
indicated.
76. Tighten the cylinder head bolts (cont.).

2 x 90°.
77. Tighten the auxiliary cylinder head bolts.
Install camshafts
78. Set piston number one to about 25mm before
TDC.
Position of the crankshaft belt pulley/vibration
damper.
79. Install the camshafts.
CAUTION:
Before the camshafts are installed number
one piston must be about 25 mm before
TDC.
CAUTION:
Wait 15 minutes before turning the engine.
Oil the bearings.

1. Fit the hydraulic tappets.
2. Fit the camshafts so that none of the cams is at
full lift.
NOTE:
R is the inlet side, L the exhaust side.
3. Fit the camshaft bearing caps so that the position

marking can be read from the rear.
• Fit the chain guide bracket with the front camshaft
bearing caps.
Install timing chain

80. Bring the camshafts and crankshaft to TDC.
CAUTION:
Partly or fully unlatched hydraulic plungers
(new or used) must not be installed.
81. Check the new chain tensioner hydraulic plunger.
1. Plunger latched.
2. Plunger partially released.
3. Plunger fully released (the detent ring is visible).
CAUTION:
Only use new and latched hydraulic
plungers.
82. Install the chain tensioner hydraulic plunger.
83. Insert the timing chain with the chain guide.
Do not secure the chain guide yet.
84. Fit the timing chain at the bottom.
• Slide the sprocket on approx. 10 mm.
• Lay the timing chain around the inner sprocket.
• Fit the Woodruff key in the crankshaft.
85. Tighten the chain guide bolts.
86. Install the chain tensioner.

1. Position the chain tensioner.
2. Insert the pivot pin.
3. Fit the circlip.
87. Position the camshaft sprockets.

NOTE:
The copper plated chain links must line up
with the marks on the sprockets.
NOTE:
The longer length of the timing chain must
be taut.
88. Fit the timing chain at the top.
If necessary turn the camshaft slightly.
89. Position the camshaft sprocket.
NOTE:
The copper plated chain links must line up
with the marks on the sprockets.
NOTE:
The timing chain may sag slightly between
the two camshaft sprockets.
Screw in both camshaft sprocket bolts finger tight.
91. Clip a new upper timing chain guide into the

bracket.
92. Release the chain tensioner hydraulic plunger.

• Press the chain tensioner arm down by hand and
release the plunger.
• If the chain tensioner arm does not reach the
hydraulic plunger then the plunger must be released
using an auxiliary tool.
93. Fabricate an auxiliary tool.

Use a 2,5 mm length of 220 mm welding rod.
94. Tighten the camshaft sprockets.

95. Check the valve timings.
• Turn the engine in the normal direction of rotation
and line up the sprockets on the mark.
• If it is necessary to correct the valve timings, i.e.
release the timing chain, a new hydraulic plunger
must also be fitted for the chain tensioner.
96. Additional check.

1. Turn the engine to the next TDC position.
2. The marks on the sprockets must be directly
opposite each other level with the cylinder head top
edge.
97. Install the oil pump drive assembly.

1. Lay the drive chain on the crankshaft sprocket.
2. Fit the oil pump sprocket and drive chain.
98. Fit a new timing chain lower cover with integral

gasket and radial oil seal.
• Put the new lower cover in place using the centring
cap.
• Tighten the bolts.
• Remove the centring cap.
CAUTION:
The correct torque is imperative.
NOTE:
Lock the crankshaft using Special Tool 21‐168
on the flywheel.
99. Install the crankshaft pulley/vibration damper.
100. Install the coolant pump using a new gasket.
101. Fit the timing chain upper cover using a new

gasket.
The upper edge of the upper cover must lie at a
maximum of 0,13 mm below the sealing face of the
cylinder head cover.
102. Fit the PCV tube.

103. Install the cylinder head cover using a new
gasket (eleven bolts and four nuts).
104. Install the engine lifting eyes.
Cylinder Head ‐ Remove and Install (21

Transit 1995 (08/1994-07/2000)
163 0)
Print

Special Tools
24‐003Remover and installer,

radiator hose clip
21‐540Angle gauge
holding wrench
Remove
1. General note.
Use remover and installer 24‐003 when removing
and installing coolant or ventilation hoses if necessary.
• Make a note of the radio keycode.
• Make a note of the preset radio stations.
• Remove the battery cover.
CAUTION:
Disconnect the battery negative lead.
WARNING:
Wrap a thick cloth around the coolant
expansion tank cover before opening the
cooling system when the engine is at
operating temperature in order to prevent
scalding.
• Open the coolant expansion tank.
3. Raise the vehicle and detach the engine
undershield. Lower the vehicle.
WARNING:
Danger of scalding when engine is at
operating temperature
4. Drain off the coolant.
5. Detach the front exhaust pipe from the exhaust
manifold.
6. Remove the exhaust pipe mountings.
7. Lower the vehicle.

8. Detach the throttle cable.
9. Disconnect the fuel lines.
10. Disconnect the central connectors.
1. Engine main wiring loom
2. Transmission main wiring loom
11. Detach the heater hose from the coolant pump.
12. Detach both heater hoses from the bulkhead.

Use a pair of angled long‐nosed pliers to press
together the collars on the plastic inserts and pull off
the hose.
13. Disconnect the wiring and detach the engine main
wiring loom.
1. Temperature gauge sender unit
2. Engine coolant temperature (ECT) sensor.
3. From the throttle position (TP) sensor.
4. From the idle speed control (ISC) valve.
14. Remove the evaporative emission return valve
bracket.
1. Detach the coolant hose from the bracket.
2. Pull off the connector and vacuum hoses.
3. Remove the bolts.
15. Disconnect the vacuum hose to the brake servo.

16. Remove the oil dipstick tube.
17. Remove the camshafts (refer to Operation
Number 21 284 0).
18. Take out the upper bolt from the timing chain
lower cover.
CAUTION:
Allow the cylinder head to cool down to at
least 30 °C before undoing the bolts.
NOTE:
Only reuse cylinder head bolts which have
integral washers (see following operation).
NOTE:
Release the auxiliary bolts first (x 3).
19. Unscrew the cylinder head bolts in the sequence

indicated.
20. Cylinder head bolts, distinguishing features.

Install
21. Preparations.
Clean all the mating faces and re‐usable parts
thoroughly and check them for damage.
22. Bring piston no. 1 to 25 mm before TDC.
1. Insert the locating bushes.
2. Lay a new cylinder had gasket in place.
CAUTION:
Do not reuse old cylinder head bolts which
have separate washers.
24. The new bolts with integral washer may be reused
providing that 174.3 mm distance is not exceeded and
the cylinder head bolts show no signs of damage.
1. New cylinder head bolts
2. Old cylinder head bolts
25. Tighten the cylinder head bolts in the sequence

indicated.
26. Tighten the cylinder head bolts (ctd.).
2 x 90°.
27. Tighten the auxiliary cylinder head bolts.

28. Install the camshafts (refer to Operation Number
21 284 0).
29. Tighten the upper bolts on the lower timing chain
guide.
30. Install the oil dipstick tube.
31. Connect the central connectors.

1. Engine main wiring loom.
2. Transmission main wiring loom.
32. Install the evaporative emission return valve

bracket.
NOTE:
The retaining lug must be inserted in the
body when fitting the bracket.
1. Position the bracket and screw in the bolts.
2. Push on the vacuum hoses and connector.
3. Attach the coolant hose to the bracket.
33. Attach the vacuum hose leading to the brake
servo.
34. Attach the engine main wiring loom and connect

the wiring.
1. Temperature gauge sender unit
2. ECT sensor.
3. TP sensor.
4. ISC valve.
35. Install the heater hoses.
NOTE:
Oil seals on the quick‐release couplings.
1. Push the coolant hoses on at the bulkhead.

2. Fit the coolant hose on the coolant pump.
36. Attach the throttle cable.
37. Connect the fuel lines.
38. Bolt on the front exhaust pipe using new gaskets.
39. Install the exhaust pipe mountings.
40. Standard finishing operations.

• Check the routing of the cables and hoses and secure
them with cable ties as necessary.
• Close the coolant drain cock.
• Fill up with coolant.
• Connect the battery negative lead.
• Bleed the cooling system.
• Check the fluid levels and rectify as necessary.
• Enter the radio keycode.
• Program the preset radio stations.
• Reset the clock.
• Carry out a road test to allow the PCM (EEC V) to
collect data.
• Check the engine and cooling system for leaks
(visual check).
• Fit the engine undershield.
Valve Seat ‐ Cut (valve removed) (21

Transit 1995 (08/1994-07/2000)
231 9)
Print

Proprietary Tools
Valve seat cutter (fixed in the valve guide)
Cutting heads: 25°, 45° and 70°
1. Locations of the angles on the valve seat.
1. Upper correction angle (70°).
2. Valve seat angle (45°).
3. Lower correction angle (25°).
4. Valve seat width
NOTE:
Only use tools which locate firmly in the
valve guide and guarantee stability.
NOTE:
The process is shown using a proprietary
tool. Follow the tool manufacturer's
instructions for use.
2. Insert the guide peg in the valve guide and tighten
it.
3. Put on the turning handle and valve seat cutter.
NOTE:
Avoid chatter marks.
4. Cutting procedure.
NOTE:
Do not remove more than 0,1 mm of
material, otherwise renew the cylinder head.
• Put on the 45° cutting head with the handle and turn
it clockwise evenly while applying an even pressure of
about 2 Kg.
• Repeat this procedure until an even surface on the
seat is achieved.
5. Check the valve seat width and contact surface.
• Make four pencil lines across the valve seat,
distributed equally around the circumference.
• Put the valve in place and turn it through 90°.
• The valve seat width, the position of the valve seat
surface on the valve and the evenness of the contact
surface can all be seen by the spread of the pencil
marks.
• If necessary repeat the cutting procedure.
6. Correct the position and width of the valve seat
area.
NOTE:
The contact area on the valve seat should
lie centrally on the seat area on the valve.
• The seat width and position of the contact surfaces
can be changed by reworking the correction angle
(see step ).
• The seat width will be narrowed and its centre line
moved towards the valve stem when the lower
correction angle (25°) is reworked.
• Recutting the upper correction angle 70°) will also
narrow the seat width, but moves its centre line
towards the valve head.
Camshafts ‐ Remove and Install (21 284

Transit 1995 (08/1994-07/2000)
0)
Print

Special Tools
holding wrench
24‐003Remover, radiator
hose clamps
21‐226Pliers, spark plug

connectors
Materials
Silicone grease A960‐M1C171‐AA
Remove
1. General note.
Use remover and installer 24‐003 when removing
and installing coolant or ventilation hoses if necessary.
• Remove the battery cover.
CAUTION:
WARNING:
Wrap a thick cloth around the coolant
expansion tank cover before opening the
cooling system when the engine is at
operating temperature in order to prevent
scalding.
• Open the coolant expansion tank.
3. General Notes.
Renew all self locking nuts.
4. Raise the vehicle, remove the engine undershield.
Lower the vehicle.
WARNING:
Danger of scalding when engine is at
operating temperature
6. Remove the intake pipe.
• Unclip the coolant hose.
• Detach the hose clamp from the throttle housing.
• Pull off the intake air temperature (IAT) sensor.
7. Remove the intake pipe (cont.).
• Disconnect the multiplug from the mass air flow
(MAF) sensor.
• Take out the intake pipe bracket bolt.
• Open two clips, pull the intake pipe out of the air
cleaner housing and remove it.
8. Detach the positive crankcase ventilation (PCV)

hose.
9. Pull off the camshaft position (CMP) sensor
multiplug.
10. Detach the coolant expansion tank and EGR

control retaining plate.
Lay the coolant expansion tank to one side.
11. Pull off the electrical and vacuum connections for

the EGR control.
1. DPFE sensor multiplug.
2. Vacuum switching valve multiplug.
3. Vacuum hose from the vacuum switching valve.
4. Vacuum hose from the EGR valve.
5. Vacuum hoses from the EGR pipe system.
12. Disconnect the electrical connections at the fan

motor.
• Fan motor multiplug.
• Ballast resistor multiplug.
13. Disconnect the coolant hose from the thermostat
housing.
If necessary use Special Tool 24‐003.
14. Remove the radiator.
• The radiator is a push‐fit at the bottom.
• Detach the coolant hose.
• Pull the radiator forwards and lift it out.
15. Detach the heater hoses at the bulkhead.

Use a pair of angled long‐nosed pliers to press
together the collars on the plastic inserts and pull off
the hose.
16. Disconnect the electrical connections and detach

the engine main wiring loom.
CAUTION:
Do not pull on the cable when removing the
spark plug connectors. Remove the high‐
tension lead from the ignition coil to prevent
kinks in the lead if necessary. Turn the spark
plug connectors slightly before removing
them in order to loosen the seal.
CAUTION:
Remove the spark plug connectors in a
straight line in relation to the spark plugs
(use special tool 21‐226 for offset spark plug
connectors).
Disconnect the HT leads from the spark plugs.
1. EI coil connectors.
2. From the injectors.
17. Detach the cylinder head cover.
18. Detach the timing chain upper cover.

NOTE:
The mark on the crankshaft pulley/vibration
damper must point straight up.
19. Bring the engine to TDC.
20. Unclip the timing chain guide.

The timing chain upper guide must be renewed on
re‐assembly.
21. Remove the camshaft sprockets.
22. Remove the chain tensioner.

1. Pull off the circlip using pliers.
2. Pull out the chain tensioner pivot bolt using an M6
bolt.
3. Take the chain tensioner arm out of the housing.
CAUTION:
Do not re‐use the chain tensioner hydraulic
plunger.
23. Remove the chain tensioner hydraulic plunger.
24. Remove the camshafts.

• Remove the timing chain guide bracket with the
front bearing caps.
• Remove the hydraulic tappets and keep them in
order.
Install
25. Position piston number one 25 mm before TDC.
Position of the crankshaft belt pulley/ vibration
damper.
26. Install the camshafts.
CAUTION:
Number one piston must be about 25 mm
before TDC before fitting the camshafts.
CAUTION:
Wait 15 minutes after fitting the camshafts
before turning the engine.
Oil the bearings.
1. Insert the hydraulic tappets.
2. Fit the camshafts so that none of the cams is on
full lift and the cut‐outs are facing outwards.
NOTE:
R is the inlet side, L is the exhaust side.
3. Fit the camshaft bearing caps so that the position

marking is readable from the rear.
Install the timing chain guide bracket with the front
bearing caps.
Install timing chain

27. Bring the engine to TDC.
The mark on the pulley/vibration damper must
point straight up.
CAUTION:
Partly or fully unlatched hydraulic plungers
(new or used) must not be installed.
28. Check the new chain tensioner hydraulic plunger.
1. Plunger latched.
2. Plunger partially unlatched.
3. Plunger fully unlatched (the detent ring is visible).
CAUTION:
Use only a new, latched chain tensioner
hydraulic plunger.
29. Install the chain tensioner hydraulic plunger.
1. Position the chain tensioner.
2. Insert the pivot pin.
3. Fit the circlip.

NOTE:
The timing chain must be taut on the long
side.
NOTE:
The copper coloured chain links must be
level with the markings on the sprockets.
Turn the camshaft slightly if necessary.

NOTE:
The timing chain may hang down slightly
between the two camshaft sprockets.
NOTE:
The copper coloured chain links must line up
with the markings on the sprockets.
34. Fit the timing chain at the top (continued).
35. Put in the camshaft sprocket bolts finger tight.
36. Clip a new timing chain upper guide into the

bracket.
37. Release the chain tensioner hydraulic plunger.

• Press the chain tensioner arm down by hand and
unlatch the hydraulic plunger.
• If the chain tensioner arm does not reach the
plunger, release it using the auxiliary tool (see step ).
38. Fabricate an auxiliary tool.
Use a 2,5 mm length of 220 mm welding rod.
39. Tighten the camshaft sprockets.
40. Checking the valve timings.

and line up the sprockets on the mark.
• If it is necessary to correct the valve timing, i.e.
release the timing chain, a new chain tensioner
hydraulic plunger must be fitted.
41. Additional check.

to the next TDC position.
• The marks on the camshaft sprockets must face
each other exactly level with the upper edge of the
cylinder head.
42. Fit the timing chain upper cover using a new

gasket.
The upper edge of the cover must be no more than
0,13 mm below the cylinder head cover mating
surface.
43. Fit the cylinder head cover with a new gasket (11
bolts and 4 nuts).
44. Make the electrical connections.

1. Connectors on the EI coils.
2. Injectors.
CAUTION:
Use a blunt object to apply the silicone
grease (e.g. a plastic cable tie) so as not to
damage the spark plug connector seal.
CAUTION:
Push on the spark plug connectors in a
straight line in relation to the spark plugs.
NOTE:
Coat the inside of the spark plug connectors
with silicone grease (A960‐M1C171‐AA) down
to a depth of 5‐10 mm.
Push on the spark plug connectors and insert them
into the guide.
NOTE:
Oil seals on the quick‐release couplings.
45. Fit the heater hoses at the bulkhead.
46. Fit the radiator.

• Insert the radiator from above.
• The radiator is a push‐fit at the bottom.
• Fit the coolant hose.
• If necessary use Special Tool 24‐003.
47. Make the electrical connections at the fan motor.

1. Fan motor multiplug.
2. Ballast resistor multiplug.
48. Fit the coolant hose at the thermostat housing.
49. Push on the electrical and vacuum connections

for the EGR control.
1. DPFE sensor multiplug.
2. Vacuum switching valve multiplug.
3. Vacuum hose to the vacuum switching valve.
4. Vacuum hose to the EGR valve.
5. Vacuum hoses to the EGR pipe system.
50. Detach the coolant expansion tank and the EGR
control bracket.
51. Fit the PCV hose.

52. Push on the CMP sensor multiplug.
53. Install the intake pipe.

• Place the intake pipe into the air cleaner housing.
• Close the two clips.
• Push the connector on the MAF.
• Bolt on the intake pipe bracket (one bolt).
54. Install the intake pipe (cont.).

• Fit the hose clip at the throttle housing.
• Clip the coolant hose in place.
• Push on the IAT sensor multiplug.

• Check the routing of the cables and vacuum hoses
and secure them with cable ties if necessary.
• Close the coolant drain cock.
• Check the fluid levels and rectify as necessary.
• Program the pre‐set radio stations.
• Carry out a road test to allow the PCM (EEC V) to
collect data.
(visual check).
Print
Specifications
Engine data
General
Identification code '95 model year 4FA
Identification code, vehicles up to 2.8 t '95 model year 4FC
Identification code, LDT (light/medium
'95 model year 4FB
commercial)
Identification code, LDT (light/medium
'97 model year 4FD
commercial)
Emission standard: 4FA A13
Emission standard: 4FC 93 EEC
Emission standard: 4FB 95/97 EEC
Emission standard: 4FD 97 EEC
Injection sequence (cylinders numbered from
1‐2‐4‐3
front to rear)
Bore 93,67 mm
Stroke 90,54 mm
Cubic capacity 2496 cm3
Compression ratio 20,8 : 1
Power output (EEC) 51 kW
Power output (EEC) 70 PS
at rev/min 4000
Torque (EEC) 146 Nm
at rev/min 2500
Idle speed 850 ± 25
Max. permissible engine speed Intermittent rev/min 4400
Location of engine code on cylinder block
 1 Engine code
 2.5 diesel engine 70 PS: 4FB/4FC
 2 Engine serial number
Dimensions
Note
Dimensions: refer to General Specifications ‐ 2.5 Turbocharged Diesel Engine (85 PS)
Lubricants, Adhesives, Coolant and Sealers
Description Ford
Specification
Grease for mounting surface of timing belt tensioner SM1C‐4515‐A
Thread‐locking compound ‐ Loctite 270 SDM‐4G‐9107‐A
Sealer, non‐setting ‐ Hylomar PL32M SPM‐4G‐9112‐F
Coolant concentrate Super‐Plus 4 ESD‐M97B‐49‐A
Capacity
Description Litres
Engine oil ‐ initial fill with filter 7
Engine oil, oil change excl. filter 5,7
Engine oil ‐ oil change with filter change 6
Coolant 11,5
Engine oil
Viscosity/ambient Designation Specification
temperature
Ford Super Multigrade Engine ACEA A2‐96/B2‐96 or A3‐
SAE 10W30 / ‐20 to over 40°C
Oil 96/B3‐96 or API/SH/CD EC
Ford Formula S Synthetic ACEA A3‐96/B3‐96 or
SAE 5W40 / ‐30 to over 40°C
Engine Oil API/SH/CD EC
Ford XR+ High‐performance ACEA A3‐96/B3‐96 or
SAE 10W40 / ‐20 to over 40°C
High‐lubricity Engine Oil API/SH/CD EC
SAE 15W40 / ‐15 to over 40°C
Oil 96/B3‐96 or API/SG/CD
Ford Formula E Economy ACEA A1‐96/B1‐96 and WSS‐
Engine Oil M2C912‐A1
NOTE:
The engine oil to specification SAE 5W30 has only been approved for use in northern
European territories.
If engine oils with these specifications are not available, use only engine oils which conform
to specifications API SH/CD EC and CCMC PD2 or better.
Torques
Bracket for front exhaust pipe 24 18
Torques
Temperature gauge sender unit 15 11
Coolant hose bracket 23 17
Torques
Exhaust gas recirculation (EGR) Nm lbf.ft
EGR pipe 23 17
Intake air pipe to bracket 23 17
Torques
Cylinder head to cylinder block, stage 1 70 52
Cylinder head to cylinder block, stage 2 70 52
Cylinder head to cylinder block, stage 3 90° 90°
Fuel filter 17 13
Fuel injection pipe nuts 19 14
Torques
Cylinder head cover, stage 1 7 5
Cylinder head cover, stage 2 7 5
Rocker shaft bearing pedestal bolts, M8 29 21
Rocker arm adjusting bolt, min. 12 9
Rocker arm adjusting bolt, max. 48 35

Transit 1995 (08/1994-07/2000)
163 0)
Print

Special Tools
21‐540Angle gauge, bolt

tightening
24‐003Remover/installer,
coolant hose clip
Proprietary Tools
New 6 mm twist drill bit
Feeler gauge
Micrometer screw
Materials
Thread‐locking
compound (Loctite SDM‐4G‐9107‐A
270)
Bolt with 19 mm head
Coolant concentrate
ESD‐M97B‐49‐A
Super‐Plus 4
Remove
1. Standard preparatory measures
• Note the pre‐set radio stations.
CAUTION:
WARNING:
There is a risk of scalding when the engine is
hot.
Remove the blanking plug from the coolant
expansion tank.
2. Raise the vehicle.
3. Detach the engine undershield.
4. Detach the front exhaust pipe.
1. Unscrew and remove the nuts.
2. Detach the bracket.
WARNING:
There is a risk of scalding when the engine
is hot.
6. Drain the coolant.
7. Pull off the oil filler cap.
8. Detach the coolant hoses.
9. Remove the intake air pipe.
10. Remove the throttle valve linkage.
11. Detach the EGR tube together with the throttle

body.
12. Detach the fuel pipe from the flame start glow plug
and disconnect the multiplug.
13. Remove the temperature gauge sender unit.

Disconnect the multiplug.
CAUTION:
When undoing the pipes use a suitable
spanner to stop them from turning.
CAUTION:
Close off all openings with dust caps.
14. Detach the injection pipes from the injectors.

15. Pull off the leak‐off hoses and the leak‐off return
hose.
16. Detach the injection pipes from the injection
pump.
17. Detach the fuel filter.
18. Detach the coolant hose bracket (one bolt).
19. Detach and unclip the heater coolant hose.
NOTE:
Lay the push rods and valve caps in order to
one side.
21. Remove the rocker shaft.
• Withdraw the push rods.
• Seal off the push rod bores.
• Take off the valve caps.
23. Unscrew and remove the timing belt upper cover
retaining bolt.
NOTE:
Cylinder head bolts can be used up to three
times. If two punch marks are already
present on a bolt then the bolt in question
should be renewed.
24. Using a centre punch, mark the heads of all the
cylinder head bolts which are to be re‐used.
NOTE:
Loosening sequence.
25. Detach the cylinder head.
Install
26. Lay a new cylinder head gasket in place.
• Clean the sealing surfaces on the cylinder head and
the cylinder block.
• Guide sleeves help to correctly locate the cylinder
head gasket in place.
27. Place the cylinder head in place.
The guide sleeves must locate in the cylinder head.
NOTE:
The cylinder head bolts may be used up to
three times. If two punch marks are already
present on a bolt then the bolt in question
should be renewed.
28. Tighten the cylinder head bolts in two stages in
the indicated sequence.
Slightly oil the threads and lower faces of the bolt
heads.
NOTE:
Draw a line across bolts 11, 12, 15 and 16
and tighten them through 90° with a socket
wrench (the special tool cannot be used
here).
29. Tighten the cylinder head bolts to stage 3. Refer to
step for the tightening sequence.
30. Install the temperature gauge sender unit.

31. Tighten the timing belt upper cover retaining bolt.
32. Install the rocker shaft.

• Insert the valve caps and push rods in the order in
which they were removed.
• Lay the rocker shaft in place.
NOTE:
First tighten the M10 bolts.
1. Five M10 bolts.

2. Four M8 bolts.
33. Adjust the valve clearances.

• Rotate the crankshaft until the valve pairs given in
the left‐hand column below are fully open.
• Open valves ‐> valves to be adjusted
1 and 6 ‐> 4 and 7
2 and 3 ‐> 5 and 8
4 and 7 ‐> 1 and 6
5 and 8 ‐> 2 and 3
34. Adjust the valve clearances (continued).
Adjust the corresponding pair of valves in the right
hand column (refer to step ).
NOTE:
The adjusting bolts must have a specified
minimum torque. Renew the bolt(s) if
necessary.
1. Adjust the adjusting bolt on the rocker shaft with a
socket wrench.
2. Exhaust valve clearance: 0,38 mm
3. Inlet valve clearance: 0,20 mm
4. There must be a very slight resistance when
inserting the feeler gauge between the valve cap and
the rocker arm.
NOTE:
Clean the gasket, and inspect it for
damage. Renew it if necessary (it can be
re‐used several times).
NOTE:
Tightening sequence.
35. Fit the cylinder head cover.
36. Attach the heater coolant hose and clip it in place.
37. Fit the bracket for the coolant hose (one bolt).
38. Fit the fuel filter.
39. Attach the injection pipes to the injection pump.
CAUTION:
When tightening the pipes use a suitable
wrench to stop them from turning.
40. Connect the fuel injection lines to the injectors.
41. Push on the leak‐off hoses.
42. Install the temperature gauge sender unit and
push on the connector.
43. Install the EGR pipe with a new gasket together

with the throttle body.
44. Connect the multiplug and the fuel pipe to the
flame start glow plug.
45. Install the throttle valve linkage.
46. Install the intake air pipe.
Adjust the EGR system

47. Set up a 20 mm measuring gauge.
• Set up the measuring gauge using a 19 mm bolt
head and a feeler gauge.
• Check the required gauge of 20 mm with a
micrometer.
48. Adjust the EGR system

1. Insert the 20 mm gauge between the stop of the
injection pump and the cam plate of the adjusting
lever.
2. Insert a 6 mm twist drill bit into the bore in the
throttle housing.
3. If necessary twist the throttle valve linkage until
the drill bit can be inserted in the bore.
Tighten the lock nuts on the throttle valve linkage.
49. Check the adjustment as described in step
50. Attach the coolant hoses.

51. Push on the oil filler cap.

53. Install the front exhaust pipe with new gasket.
54. Carry out an oil change.

55. Install the lower engine cover.
• Check that the vacuum hoses and cables are
correctly routed and secure them with cable ties if
necessary.
• Check fluid levels and correct as necessary.
• Reprogram the preset radio stations.
• Carry out a road test to enable the EPIC module to
collect data.
(visual check).
Seals ‐ Valve Stem ‐ Renew (21 238 0) Transit 1995 (08/1994-07/2000)
Print

Special Tools
21‐156Installer, valve collets
21‐158Valve spring
compressor
21‐165Pliers, valve stem oil

seals
Proprietary Tools
Feeler gauge
Micrometer
Valve stem installation sleeves
Materials
Bolt with 19 mm head
Remove
1. Preparatory measures.
CAUTION:
2. Pull off the oil filler cap.

4. Remove the exhaust gas recirculation (EGR) pipe.

Unclip the heater coolant hose.
NOTE:
Lay the push rods and valve caps in order to
one side.
• Pull out the push rods.
• Seal off the push rod holes.
• Take off the valve caps.
7. Turn the crankshaft to TDC position.

Mark the position.
NOTE:
Carry out the following steps on cylinders 1
and 4 only:
8. Remove the valve springs.
• Compress the valve springs.
• Remove the valve collets.
• Take out the valve spring retainers and valve springs
and lay them in order to one side.
9. Remove the valve stem oil seals.
Install
CAUTION:
Slide the installation sleeves over the grooves
on the valve stems.
10. Coat the new valve stem oil seals with engine oil
and install them.
After installation remove the installation sleeves.
11. Install the valve springs.

Insert the valve springs and valve spring retainers.
1. Compress the valve springs.
2. Insert the valve collets into the grooves on the
valve stems.
12. Set cylinders 2 and 3 to TDC.

13. Repeat steps to on cylinders 2 and 3.
14. Check the seating of the valve collets.

• Insert the valve caps and push rods according to the
sequence in which they were removed.
• Lay the rocker shaft in place.
NOTE:
First tighten the M10 bolts.
1. Five M10 bolts.

2. Four M8 bolts.

• Rotate the crankshaft until the valve pairs given in
the left‐hand column below are fully open.
1 and 6 ‐> 4 and 7
2 and 3 ‐> 5 and 8
4 and 7 ‐> 1 and 6
5 and 8 ‐> 2 and 3
Adjust the corresponding pair of valves in the right
hand column (refer to step ).
NOTE:
necessary.
1. Adjust the adjusting bolt on the rocker arm with a
socket wrench.
2. Exhaust valve clearance: 0,38 mm
3. Inlet valve clearance: 0,20 mm
4. There must be a very slight resistance when
inserting the feeler gauge between the valve cap and
the rocker arm.
NOTE:
Clean the gasket, and inspect it for damage.
Renew it if necessary (it can be re‐used
several times).
NOTE:
Tightening sequence.

Attach the heater coolant hose and clip it in place.
19. Fit the EGR pipe using a new gasket.

20. Fit the bracket for the intake air pipe.
21. Fit the intake air pipe.

22. Attach the oil filler cap.
Adjust the EGR system.

23. Make up a 20 mm measuring gauge.
• Set up the measuring gauge using a 19 mm bolt
head and a feeler gauge.
• Check the required gauge of 20 mm with a
micrometer.
24. Adjust the EGR system.
1. Insert the 20 mm gauge between the fuel injection
pump stop and the adjusting lever cam plate.
2. Insert a 6 mm twist drill bit into the bore in the
throttle housing.
3. If necessary twist the throttle valve linkage until
the drill bit can be inserted in the bore.
Tighten the lock nuts on the throttle valve linkage.
25. Check the adjustment as described in step

gather data.
Print
Specifications
Engine data
General
Identification code '95 model year 4HB
Identification code '97 model year 4HC
Emission standard: 4HB 95/97 EEC
Emission standard: 4HC 97 EEC
1‐2‐4‐3
front to rear)
Bore 93,67 mm
Stroke 90,54 mm
Cubic capacity 2496 cc
Compression ratio 20.8 : 1
Power output (EEC) 76 (PS)
at rev/min 4000
Torque (EEC) 168 Nm
at rev/min 2500
Intermittent rev/min 4400
Location of engine code on cylinder block
 1. Engine code
 2.5 diesel engine (76 PS): 4HB
 2. Engine serial number
Dimensions
Note:
Dimensions: refer to General Specifications ‐ Turbocharged Diesel Engine 85 PS
Lubricants, Adhesives, Coolants and Sealers
Description Ford
Specification
High‐temperature grease for input shaft splines and for sliding surface of
ESD‐M1C220‐A
clutch release bearing on guide sleeve
Grease for mounting surface of timing belt tensioner SM1C‐4515‐A
Super‐Plus 4 Coolant Concentrate ESD‐M97B‐49‐A
Sealer, non‐hardening ‐ Hylomar PL32M SPM‐4G‐9112‐F
Capacity
Description Litres
Engine Oil ‐ Initial fill incl. filter 7
Engine Oil ‐ Oil change incl. filter change 6
Coolant 11,5
Engine oil
Viscosities/Ambient Designation Specification
Temperature
SAE 10W30 / ‐20 to over 40 Ford Super Multigrade Engine ACEA A2‐96/B2‐96 or A3‐
degrees Centigrade Oil 96/B3‐96 or API/SH/CD EC
SAE 5W40 / ‐20 to over 40 Ford Formula S Synthetic ACEA A3‐96/B3‐96 or
degrees Centigrade Engine Oil API/SH/CD EC
SAE 10W40 / ‐20 to over 40 Ford XR+ High Performance‐ ACEA A3‐96/B3‐96 or
degrees Centigrade High Lubricity Engine Oil API/SH/CD EC
degrees Centigrade Oil 96/B3‐96 or API/SG/CD
SAE 5W30 / ‐20 to over 10 Ford Formula E Economy ACEA A1‐96/B1‐96 and WSS‐
degrees Centigrade Engine Oil M2C912‐A1
NOTE:
Use of engine oil with the specification SAE 5W30 is only permitted in north European
countries.
If engine oils with these specifications are not available, only oils which conform to or
exceed the API SH/CD EC and CCMC PD2 specifications may be used.
Torques
General Nm lbf.ft
Bracket of front exhaust pipe 24 18
Hood lock panel with radiator 11 8
Support brace to crossmember 11 8
Torques
Inlet manifold Nm lbf.ft
Plenum chamber halves 23 17
Inlet manifold bracket to exhaust manifold 23 17
Inlet manifold to cylinder head 23 17
Torques
Exhaust manifold to cylinder head 48 36
Threaded studs of exhaust manifold 23 17
Torques
Alternator Nm lbf.ft
Drive belt tensioning strap 24 18
Alternator mounting bolt 24 18
Alternator bracket 19 14
Alternator clamp bolt 24 18
Torques
Driveshaft centre bearing to floor assembly 33 24
Shift lever to transmission housing 25 19
Transmission to engine 35 26
Fuel line bracket to transmission flange 35 26
Clutch housing front cover 25 19
Clutch housing adaptor plate 10 7
Transmission to rear transmission mounting 84 62
Bolt/nut of rear transmission mounting to transmission crossmember 84 62
Nut of rear transmission mounting to transmission 50 37
Starter motor to transmission flange 35 26
Starter motor ground cable to transmission flange 35 26
Torques
Water pump pulley 10 7
Fan pulley 10 7
Coolant drain plug 23 17
Engine coolant temperature sensor (ECT sensor) 13 10
Torques
Steering Nm lbf.ft
Clamp bolt of steering intermediate shaft 30 22
Steering gear to crossmember 50 37
Power steering pump mounting bolt 23 17
V‐belt clamp bolt 23 17
Torques
Oil pressure regulating valve 56 41
Oil pump to adaptor plate 19 14
Oil pump housing to cylinder block 19 14
Oil pump housing retaining plate 23 17
Sump to cylinder block 14 10
Oil cooler 70 52
Vacuum pump oil pressure pipe 21 15
Torques
EGR pipe to exhaust manifold 23 17
Torques
Engine mounting bracket to cylinder block 55 41
Engine mounting bracket to transmission 62 46
Engine mounting nuts 50 37
Torques
Fuel system Nm lbf.ft
Fuel pump to cylinder block 23 17
Fuel pump heat shield 23 17
Fuel injection pump to adaptor plate 23 17
Fuel injection pump rear bracket 23 17
Fuel line to fuel injection pump 18 13
Fuel filter 17 12
Fuel injection pump timing belt pulley 25 19
Fuel injection pipes 19 14
Torques
Camshaft rear cover to cylinder block 23 17
Front pressure plate/bracket to cylinder block 23 17
Cylinder head to cylinder block ‐ Stage 1 70 52
Cylinder head to cylinder block ‐ Stage 3 90° 90°
Engine adaptor plate to cylinder block ‐ bolts 1 ‐ 8 36 27
Engine adaptor plate to cylinder block ‐ bolt 9 23 17
Starter motor to cylinder block 35 26
Crankshaft rear oil seal housing to cylinder block 19 14
Allen screws ‐ rear oil seal housing 14 10
Camshaft timing pulley ‐ 1st stage 10 7
Camshaft timing pulley ‐ 2nd stage 160 118
Big‐end bearing caps ‐ Stage 1 56 41
Big‐end bearing caps ‐ Stage 2 69 51
Crankshaft main bearing caps ‐ Stage 1 84 62
Crankshaft main bearing caps ‐ Stage 2 120 89
Bolt of crankshaft pulley/vibration damper 163 12
Flywheel to crankshaft ‐ Stage 1 21 15
Flywheel to crankshaft ‐ Stage 2 30° 30°
Timing belt cover to adaptor plate 7 5
Splash shield to timing belt cover 1 0,7
Timing belt tensioner clamp bolt 24 18
Tensioning pulley bolt 58 43
Water pump to adaptor plate ‐ M8 23 17
Water pump to adaptor plate ‐ M10 46 34
Timing case cover to adaptor plate 23 17
Engine adaptor plate bracket (bolts) 46 34
Engine adaptor plate bracket (bolt and nut) 23 17
Drive belt tensioning strap 24 18
Flywheel immobilising tool to cylinder block 35 26
Torques
Cylinder head cover ‐ Stage 1 7 5
Bolt for injector retaining plate 40 29
Thermostat housing to cylinder head 23 17
Thermostat housing bolts 23 17
EGR valve to throttle housing 18 13
Bypass hose to cylinder head 18 13
Engine lifting eye 23 17
Bracket for holding the engine lifting fixture 23 17
Engine ‐ Dismantle and Reassemble

Transit 1995 (08/1994-07/2000)
(engine removed) (21 134 8)
Print

Special Tools
holding wrench
16‐067Aligner, clutch disc
21‐015Mounting bracket
21‐017 AOil seal

installer/aligner
21‐102‐01Adaptor for 21‐102
21‐102‐02AAdaptor for 21‐102

21‐102‐03Oil seal
installer/aligner
21‐121Vibration damper oil

seal remover/installer
21‐123Camshaft timing pin
21‐138 AEngine lifting fixture
21‐138‐01Adaptor for 21‐138

A
21‐149Aligner/installer
21‐159Oil seal
installer/aligner
21‐540Angle gauge
23‐020Injection pump timing

pin
23‐029Injection pump timing

pin
23‐030Remover, Stanadyne
fuel injectors
23‐030‐01Adaptor for 23‐030
radiator hose clamp
Materials
Thread‐locking SDM‐4G‐9107‐A
compound (Loctite
270)
Sealer (Hylomar
SPM‐4G‐9112‐F
PL32M)
Grease SM1C‐4515‐A
From: Replacement
Services Limited, 30,
Euston Street,
Plastigage
Freemans Industrial
Estate, Leicester, LE2
7ST
Proprietary Tools
Dial indicator
Magnetic fixture
Piston ring compressor
Oil filter strap wrench
Micrometer screw
Cylinder bore gauge
Feeler gauge
32 mm open‐ended spanner
Dismantle
NOTE:
Right‐hand thread.
1. Remove the fan with the viscous clutch.

Use the 32 mm open‐ended spanner.
2. Attach the engine to the assembly stand.

Attach the mounting bracket to the cylinder block.
3. Detach the engine lifting fixture.

4. Drain off the engine oil.
5. Withdraw the oil dipstick.
6. Unscrew the high‐pressure oil pipe from the
vacuum pump.
7. Detach the oil return line from the oil pump
housing.
8. Remove the oil filter.
9. Slacken the bolts of the pulleys.
10. Take off the drive belt.

1. Slacken the bolts.
2. Slacken the drive belt at the adjusting bolt.
Take off the drive belt.
11. Remove the alternator with the tensioning

bracket.
12. Remove the water pump pulley and fan pulley.

13. Remove the rubber cover from the crankshaft
pulley/vibration damper.
14. Remove the timing belt cover.
1. Seven bolts.
2. Slacken the bolts, push the splash shield upwards
and secure it again.
15. Remove the oil cooler.

Use a 13 mm hexagonal socket.
16. Align the fuel injection pump and camshaft

pulleys.
Turn the crankshaft until the adjustment bores in
the fuel injection pump timing pulley and the
camshaft timing pulley line up with the bores in the
adaptor plate.
17. Remove the timing belt.

1. Remove the tensioning pulley bolt.
2. Release the clamp bolt.
3. Push the tensioning pulley right back and tighten
the clamp bolt again.
4. Remove the timing belt.
Unscrew the clamp bolt and remove the timing belt
tensioner.
18. Remove the clutch assembly.

19. Remove the bolt from the crankshaft
pulley/vibration damper.
CAUTION:
Do not insert the pins of the flange‐holding
wrench in the threaded holes.
Hold the flywheel still.
20. Pull off the crankshaft pulley/vibration damper.
21. Remove the thrust washer.
22. Remove the camshaft timing pulley.

CAUTION:
Never use Special Tool 21‐123 for
immobilising the camshaft timing pulley.
1. Hold the timing pulley still.
2. Unscrew the bolt and remove the timing pulley.
23. Detach the water pump from the engine adaptor

plate.
NOTE:
Keep the bolts in order.
24. Detach the oil pump housing (11 bolts).

Remove the alternator retaining plate.
25. Remove the oil pump.

1. Remove the Woodruff key.
2. Pull the oil pump drive gear off the crankshaft.
3. Turn the oil pump gear until the pump bolts are
accessible.
Remove the bolts and lift out the pump.
26. Detach the fuel line from the fuel pump.
27. Detach the fuel lines from the fuel injection

pump.
Close off the openings using suitable plugs.
28. Remove the fuel filter and pipes.

CAUTION:
Hold the lines with a suitable wrench when
releasing them.
29. Disconnect the fuel injection lines from the
injectors and the fuel injection pump.
CAUTION:
Close off all the connections with dust caps.
1. Remove the rear fuel injection lines as a pair.

2. Remove the front fuel injection lines as a pair.
30. Remove the fuel injection pump timing pulley.
31. Remove the fuel injection pump.
32. Detach the fuel injection pump rear bracket from

the fuel injection pump and the cylinder block.
33. Disconnect the bypass hose.
Detach the bracket from the cylinder block.
34. Detach the connecting pipe from the adaptor

plate.
35. Remove the Woodruff key and spacer sleeve from

the camshaft.
1. Woodruff key
2. Spacer sleeve with O‐ring
36. Detach the reinforcing bracket for the engine

adaptor plate.
37. Remove the engine adaptor plate.

1. Remove the hexagon socket head bolts from the
sump flange.
2. Remove the nine bolts.
3. Remove the O‐rings from the oil passages.
38. Remove the oil passage seal (square cross‐
section).
39. Disconnect the leak‐off hoses.
40. Remove the cylinder head cover.
41. Remove the thermostat housing.

Remove the O‐ring.
NOTE:
Keep the push rods and valve caps in order.

• Remove the valve caps.
43. Remove the injectors.
Remove the injector retaining plate.
1. Push the adaptor into the groove of the injector
body.
2. Fix the special tool to the top of the lever and pull
out the injector.
Seal the openings with suitable plugs.
NOTE:
Cylinder head bolts may not be used more
than three times. If a bolt already has two
punch marks, it should be renewed.
44. Mark all the heads of the old cylinder head bolts
with a punch.
NOTE:
Slackening order.
46. Remove the crankshaft position sensor (CKP

sensor).
1. Bolt
2. Remove the spacer (if fitted).
CAUTION:
Do not insert the pins of the flange‐holding
wrench in the threaded holes.
47. Remove the flywheel.
48. Remove the sump downwards.
• Remove the bolts.
• Remove the gasket.
49. Remove the oil intake pipe and strainer.

• Turn the engine on the assembly stand.
• Remove the O‐ring.
CAUTION:
Do not damage the cylinder bores.
50. Remove the carbon from the upper edge of the

cylinder bores.
NOTE:
Mark the positions of all parts for refitting.
51. Remove the pistons with the connecting rods.

• Unscrew the big‐end bearing caps and remove the
bearing shells.
• Remove the pistons and connecting rods upwards.
• Remove the upper big‐end bearing shells.
52. Remove the crankshaft rear oil seal housing.

• Remove the gasket.
• Carefully remove the oil seal.
53. Remove the fuel pump heat shield.
54. Remove the fuel pump.

Remove the gasket.
55. Remove
the engine
coolant
temperature
(ECT)
sensor.
56. Remove
the vacuum
pump oil
feed hose.
57. Unscrew
the oil
pressure
switch.
58. Remove
the oil
pressure
regulating
valve.
1. Remove
the valve
plugs.
2. Remove
the O‐ring.
3. Lift out
the plunger
and spring
using a thin
wire.
59. Remove the camshaft rear cover plate.
Remove the O‐ring.
CAUTION:
Do not damage the bearing bushes.
60. Remove the camshaft front thrust/ pressure

plate.
61. Lift the camshaft out of the cylinder block.
CAUTION:
Do not damage the bearing journals.
62. Remove the crankshaft.

NOTE:
Keep the bearing shells in order.
• Remove the main bearing caps, the lower bearing

shells and thrust half rings.
• Lift out the crankshaft.
• Remove the upper bearing shells and thrust half
rings.
63. Remove the valve tappets and keep them in
order.
64. Press the crankshaft oil seal out of the oil pump
housing.
65. Press the camshaft oil seal out of the engine
adaptor plate.
Use Special Tool 21‐159.
NOTE:
If the cylinder head has been machined or a
new cylinder block or a new crankshaft is
installed, the timing pin guide flange should
be removed and readjusted (see step ).
66. Remove the timing pin guide flange.
1. Remove the bolt.
2. Drill out the shear bolt.
Assemble
67. Preparatory operations.
Clean all mating faces and reusable parts thoroughly
and check them for damage.
NOTE:
If necessary, rework or renew the
crankshaft.
68. Measure the diameters of the main and big‐end
bearing journals using a proprietary micrometer.
Repeat each measurement at 90°.
69. Fit the valve tappets.

70. Fit the camshaft.
71. Fit the front thrust/pressure plate.
72. Fit the camshaft rear cover plate using a new O‐

ring.
Measure bearing clearances

CAUTION:
Do not damage the bearing shells when
fitting the crankshaft.
73. Fit the crankshaft.
• Place the bearing shells in the cylinder block.
• Place the crankshaft dry in the cylinder block.
NOTE:
The measuring point must be dry.
CAUTION:
The crankshaft must not be turned during the
measuring operation.
74. Measure the crankshaft main bearing clearance.
Lay a length of Plastigage thread on the bearing
journal across the bearing.
NOTE:
Measure the clearance of the bearings in
turn in numerical order (1 ‐ 5).
(continued).
NOTE:
The bearing cap numbering starts at the
timing belt end.
• Fit the bearing cap with the associated bearing
shell, with the arrow pointing towards the timing belt
end, and secure it.
• Detach the bearing cap.
(continued).
• Compare the Plastigage thread with the Plastigage
scale.
• The reading corresponds to the bearing clearance.
• If the specified bearing clearance is not obtained,
change the bearing shells and repeat steps to
77. Install the crankshaft.

• Lubricate the main bearing journals and bearing
shells, the thrust half rings and the threads of all the
bolts and the bolt contact faces with engine oil.
• Fit the crankshaft.
• Fit the thrust half rings.
• Coat the contact faces and sides of the rear bearing
cap with sealer.
NOTE:
The bearing cap numbering starts at the
timing belt end, to which the arrows also
point.
• Fit the crankshaft main bearing caps with the
associated bearing shells.
78. Check the crankshaft end float.
• Put a proprietary dial gauge and magnetic stand in
position.
• Check the end float as shown by lifting the
crankshaft.
• Correct the end float as necessary by fitting new
thrust half rings to main bearing no. 3.
Measure piston diameter

NOTE:
Measure the piston diameter at the level of
the piston pin bore.
79. Measure the piston diameter.
Measure cylinder bore

80. Measure the cylinder bore.
NOTE:
Six measurements per cylinder bore.
1. Cylinder head mounting face

2. Measuring point directly below the upper reversing
point of the upper piston ring.
3. Measuring point 80 mm below the cylinder head
mounting face.
4. Measuring point 165 mm below the cylinder head
mounting face.
If necessary, rebore the cylinder block or renew it.
81. Calculate the average bore diameter.
Take the average of all six measurements.
Measure piston clearance in bore

82. Measure the piston clearance in the bore.
Subtract the average bore diameter from the
corresponding piston diameter.
83. Check the piston ring gaps.
• Fit the rings, in order, in the appropriate cylinder
bore directly below the upper reversing point of the
upper piston ring.
• Measure the ring gap using feeler gauges.
84. Fit the piston rings into the pistons.
1. The ring gaps of the compression rings must be
opposite each other and must be aligned with the
piston pin axis.
2. The ”TOP" mark on the second compression ring
must face upwards, and the white mark must be to
the left of the ring gap.
3. The piston ring gap of the oil scraper ring must be
on the pressure side of the piston.
85. Piston identification.

1. Paint mark for piston pin bore.
NOTE:
The paint marks on the piston and the
piston pin must be matching.
2. Piston classification
3. The arrow points to the timing belt end.
86. Fit the pistons.

• Lubricate the pistons and cylinder bores with engine
oil.
• Compress the piston rings using a proprietary piston
ring compressor.
NOTE:
The numbering on the connecting rods starts
at the timing belt end. The arrow on the
piston crown points towards the timing belt
end.
• Press pistons 1 and 4 into the cylinders using the
handle of a hammer. The big‐end bearing journal must
be at BDC.
• Lubricate the bearing shells with engine oil.
• Place the appropriate bearing shells in the
connecting rod and bearing cap.
• Fit the bearing caps.
• Turn the crankshaft through 180°, fit pistons 2 and
3.
87. Measure the big‐end bearing clearance.
Measure the big‐end bearing clearance as described
in steps to
NOTE:
The connecting rods and big‐end bearing
caps have the same numbers.
88. Fit the big‐end bearing caps.
• Lubricate the bearing shells and bearing journals
with engine oil.
• Fit the associated big‐end bearing caps and bearing
shells and secure them.
89. Check the piston protrusion at the cylinder block
face.
• Place the plunger of the proprietary dial gauge on
the top of the piston.
• Bring the piston to be measured to the TDC
position.
• Zero the dial indicator.
• Position the plunger on the cylinder head mounting
face.
NOTE:
The oil seal housing and sump face must lie
absolutely flush to one another.
90. Fit the crankshaft rear oil seal housing with a new
gasket.
Screw in the bolts loosely.
1. Fit the special tool with the centring side (small
inside diameter) on the crankshaft journal.
2. Tighten the bolts.
91. Fit the crankshaft rear oil seal.

Fit the special tool.
92. Fit the crankshaft rear oil seal (continued).

1. Fit the oil seal with the support ring inserted.
NOTE:
The installation side of the special tool has a
larger inside diameter.
2. Fit the special tool.
3. Fit the adaptor and draw in the oil seal evenly with
the nut.
• Remove the special tool and remove the support
ring.
93. Press the camshaft oil seal into the engine

adaptor plate.
94. Fit the new oil seal (square cross‐section) in the
oil passage.
95. Fit the engine adaptor plate.

NOTE:
The adaptor plate and sump face must line
up exactly.
• Fit the adaptor plate with a new gasket.
• Press out the protective sleeve in the oil seal with
the camshaft.
NOTE:
One M8 bolt
• Screw in the nine bolts loosely.

• Push the special tool onto the camshaft and position
the adaptor plate so that the oil seal is aligned.
96. Fit the engine adaptor plate (continued).
NOTE:
The tightening torque for bolt no. 9 is
different from that of the other bolts.
Tighten the bolts in the indicated order.
97. Fit the bracket for the engine adaptor plate.

1. Bolt with nut
2. Two bolts
98. Fit the spacer sleeve and the O‐ring.

1. Fit the spacer sleeve.
2. Push the new O‐ring onto the camshaft and press
it into the groove using the centring tool 21‐159.
99. Attach the oil intake pipe and strainer using a
new O‐ring.
Turn the engine on the assembly stand.
100. Place a new sump gasket with sealer (SPM‐4G‐

9112‐F) on the sump flange.
• The four locating tabs point downwards.
• Apply a sufficient amount of sealer, particularly at
the four corners of the flange.
101. Fit the sump.

Apply a generous amount of sealer (SPM‐4G‐9112
F) in the areas indicated.
102. Turn the engine.
103. Fit the

oil pressure
regulating
valve.
Lubricate
the spring
and valve
plunger with
engine oil.
1. Fit the
spring in the
cylinder
block.
2. Insert a
new O‐ring in
the recess in
the cylinder
block.
3. Fit the
plunger in the
valve
housing.
4. Screw in
the valve
housing and
tighten it.
NOTE:
Bolts may only be reused if they have fewer
than five punch marks on the head.
104. Fit the flywheel.
NOTE:
The crankshaft locating sleeve and the bore
in the flywheel must line up.
Fit the flywheel.
CAUTION:
The pins of the flange‐holding wrench must
not engage in the threaded holes.
Pre‐tighten the bolts in pairs, working diagonally.
105. Fit the flywheel (continued).
• Tighten the bolts in pairs, working diagonally.
• Mark each of the bolt heads with a punch.
NOTE:
If the cylinder head has been machined or a
new cylinder block or new crankshaft is
fitted, the timing pin guide flange should be
removed and readjusted.
106. Turn the crankshaft to 11° before the TDC
position.
1. Position the dial indicator and stand on the cylinder
head mounting face over piston number 1.
• Bring the piston to the TDC position with the aid of
the dial indicator.
• Zero the dial indicator in this position.
• Turn the crankshaft counter to the running direction
of the engine until the pointer of the dial indicator
has made three full rotations.
• Turn the crankshaft in the running direction of the
engine until the dial indicator shows 1,103 mm before
the TDC position.
If the 1,103 mm position is exceeded, repeat step
* Fit the timing pin guide flange.
* Bring the guide flange into the installation position.
* Fit the special tool.
* Flywheel
* Tighten the shear bolt finger tight.
* Tighten the bolt.
* Remove the special tool.
* Turn the crankshaft counter to the running direction
of the engine until the pointer of the dial indicator
has made one rotation.
* Turn the crankshaft in the running direction of the
engine until the dial indicator shows 1,103 mm before
the TDC position.
* Fit the special tool.
* If the special tool cannot be inserted properly in the
flywheel and guide flange, repeat step
107. Shear off the shear bolt.
108. Fit the oil pump.
• Insert the new O‐rings in the oil passage recesses
in the cylinder block.
• Fill the oil pump with new engine oil.
NOTE:
The oil passages on the pump and the
cylinder block must line up.
Fit the oil pump.
109. Fit the oil pump (continued).

• Turn the oil pump gear wheel until the oil pump
bolts are accessible.
• Screw in the five bolts.
110. Fit the oil pump drive gear.

Apply sealer (SPM‐4G‐9112‐F) to the face of the
gear on the engine side.
1. Fit the gear to the crankshaft.
2. Fit the Woodruff key with the long side facing
upwards and the rounded end pointing towards the
cylinder block.
Install crankshaft front oil seal

111. Fit the crankshaft oil seal in the oil pump
housing.
1. Support the oil pump housing with the special tool
so that the locating tabs engage in the recess of the
tool.
2. Oil seal installer
3. Press in the oil seal.
112. Fit the oil pump housing.

Fit the support ring in the oil seal from behind.
CAUTION:
The protective sleeve must fit over the gear
shoulder.
Fit the oil pump housing to the adaptor plate with a
new gasket.
1. Crankshaft
2. Oil seal in oil pump housing
3. Protective sleeve
4. Gear shoulder
• Carefully press the oil pump housing on completely.
• Remove the protective sleeve.
113. Fit the oil pump housing (continued).
1. Fit the special tool.
NOTE:
Bolt no. 5 is longer (see step ).
2. Tighten all the bolts finger tight.

Centre the housing with the special tool.
114. Fit the oil pump housing (continued).

• Tighten the bolts in the indicated order.
• Pull off the special tool and fit it again. If the tool
cannot be inserted easily, slacken the bolts and
repeat steps to
115. Fit the oil pump housing retaining plate and

connecting pipe to the adaptor plate with a new
gasket.
• Locate the retaining plate and connecting pipe in
position.
• Screw in the bolts and tighten them.
1. Bolt and nut
2. Bolt
116. Fit the timing belt tensioner.

1. Fit the spring and sleeve to the timing belt
tensioner.
NOTE:
Keep the clamp bolt free of grease.
Coat all the contact faces of the tensioner with

grease (SM1C‐4515‐A).
2. Press the tensioner right back against the spring
and tighten the clamp bolt.
3. Tighten the tensioning pulley bolt.
117. Fit the Woodruff key in the camshaft.

NOTE:
The bolt may only be tightened six times in
all. Each time it is tightened, mark it with a
punch.
118. Fit the camshaft timing pulley.
119. Fit the fuel injection pump to the adaptor plate.
120. Fit the rear bracket of the fuel injection pump.

NOTE:
Tightening order
1. Bolts/nuts on fuel injection pump

2. Bolts on cylinder block
121. Fit the fuel injection pump timing pulley with the
reinforcing plate.
Position the bolts in the middle of the slots and
screw them in.
122. Fit the water pump with a new gasket.

1. M8 bolts, short
2. M8 bolts, long
3. M10 bolt
Install the timing belt

123. When renewing the timing belt, ensure that the
version with the correct mesh depth and width is
used.
1. Timing belt prior to '92 MY: 2.5 mm.
2. Timing belt from '92 MY onwards: 3.5 mm.
• Wider timing belt from '98 MY.
124. Align the fuel injection pump and camshaft

timing pulleys.
Fit the special tool
NOTE:
The convex side faces outwards.
125. Push the thrust washer on to the crankshaft.
126. Fit the crankshaft pulley/vibration damper.

NOTE:
The timing belt must be fitted with the
arrows pointing in the direction of rotation
of the crankshaft.
Fit the timing belt.
CAUTION:
The pins of the flange‐holding wrench must
not engage in the threaded holes.
• Fit the pulley/vibration damper.
• Fit the rubber cover.
127. Sectional view of the crankshaft pulley/vibration
damper.
1. Oil pump drive gear
2. Thrust washer
3. Crankshaft timing pulley
4. Crankshaft pulley/vibration damper
5. Rubber cover
6. Bolt ‐ belt pulley
Install clutch pressure plate
128. Centre the clutch disc.
Centre the clutch disc on the pressure plate and
attach the special tool.
129. Fit the clutch pressure plate with the clutch disc.
• Fit the pressure plate with the special tool and the
centred clutch disc to the flywheel.
• Tighten the pressure plate bolts evenly, working
diagonally.
• Remove the special tool.
130. Turn the crankshaft until the special tool can be

inserted.
NOTE:
Use a new timing belt.
131. Lay the new timing belt in place.

• Fit the timing belt over the camshaft and fuel
injection pump pulleys, making sure that it is sitting
centrally on the pulleys.
• If necessary, turn the fuel injection pump timing
pulley slightly so that the belt teeth engage properly.
132. Adjust the timing belt tension.

• Release the bolts of the timing belt tensioner and
let the tensioner spring back.
133. Tighten the bolts of the fuel injection pump
timing pulley.
134. Remove the three special tools.
135. Turn the crankshaft 1 7/8 turns clockwise.
The bolts of the fuel injection pump timing pulley
should be in the middle of the slots.
136. Adjust the timing belt tension.

1. Loosen the tensioning pulley bolt.
2. Release the clamp bolt.
3. Press the timing belt down firmly.
Tighten the two bolts.
137. Check the injection timing.

1. Turn the crankshaft in the normal direction of
rotation until the special tool can be inserted.
2. Insert the special tool.
• If necessary, release the bolts and adjust the timing
pulley slightly.
• Remove the two special tools.
138. Fit the CKP sensor.

1. Fit the spacer (if applicable).
2. Bolt
Install cylinder head

139. Fit a new cylinder head gasket.
• Clean the mating faces on the cylinder head and
cylinder block.
• The cylinder head gasket is guided into place by the
locating sleeves.
The guide sleeves must engage in the head.
NOTE:
141. Pre‐tighten the cylinder head bolts.
Lightly oil the threads and contact faces of the
cylinder head bolts.
Insert the bolts and pre‐tighten them in two stages
in the indicated order.
142. Tighten the cylinder head bolts.

NOTE:
Mark bolts 11, 12, 15 and 16 with a line and
tighten them by 90° using a socket wrench,
as the special tool cannot be used in these
positions.
Tighten the cylinder head bolts in the indicated
order.
NOTE:
If the needle injection nozzle is broken or
cracked, all four injection nozzles must be
renewed.
143. Renew the injector seals.
Remove the old injector seal with pliers.
144. Renew the injector seals (continued).

1. Renew the dust seals.
2. Insert the new injector seal in the lever of the
special tool and press the injector into the seal as far
as it will go.
145. Install the injectors.
1. The correct installation position is determined by a
locating plate attached to the injector.
2. Secure the fitted injector with the retaining plate.
3. Tighten the bolt.
146. Fit the rocker shaft.

1. Rocker arm ‐ exhaust
2. Spring
3. Rocker arm ‐ inlet
4. M8 bolt ‐ bearing pedestal
5. Bolt ‐ rocker shaft
6. M10 bolt ‐ bearing pedestal
7. Rear bearing pedestal
8. Rocker shaft
9. Push rods
10. Cylinder head
11. Valve caps
12. Front bearing pedestal
13. Core plug
Fit the valve caps and push rods in the order in
147. Fit the rocker shaft (continued).

Fit the rocker shaft.
NOTE:
Tighten the M10 bolts first.
1. M10 bolts (five off, with blue mark).

2. M8 bolts (four off, with blue mark).
Adjust valve clearances.

• Turn the crankshaft until the pair of valves indicated
in the first column are completely open.
• Open valves ‐> Valves to be adjusted
1 and 6 ‐> 4 and 7
2 and 3 ‐> 5 and 8
4 and 7 ‐> 1 and 6
5 and 8 ‐> 2 and 3
Adjust the corresponding pair of valves in the
second column.
NOTE:
The adjusting bolts must be tightened to a
specified minimum torque. Renew the
bolt(s) if necessary.
1. Adjust with the adjusting bolt on the rocker arm
using a socket wrench.
2. Valve clearance for exhaust valves: 0,38 mm
3. Valve clearance for inlet valves: 0,20 mm
4. The specified feeler gauge must just go in between
the valve cap and the rocker arm.
NOTE:
Clean the gasket and inspect it for damage.
Renew it if necessary (it can be used again
several times).
NOTE:
Tightening order
151. Fit the leak‐off hoses.
152. Fit the thermostat housing using a new O‐ring.
NOTE:
Marks on the bypass hose and connecting
pipe.
153. Fit the bypass hose.
CAUTION:
Hold with a suitable wrench while securing
the lines.
154. Connect the fuel injection lines to the injectors
and the fuel injection pump.
1. Connect the front fuel injection lines as a pair.
2. Connect the rear fuel injection lines as a pair.
156. Connect the fuel lines to the fuel injection pump.
157. Fit the fuel pump using a new O‐ring.

158. Fit the fuel pump heat shield.
159. Connect the fuel line to the fuel pump.
160. Install the ECT sensor.

161. Fit the vacuum pump high‐pressure oil line.
162. Fit the oil pressure switch.
163. Fit the timing belt cover.

Swing the lower cover up and screw in the bolts.
NOTE:
The bolts are of different lengths.
1. Long bolt.
2. Medium bolt.
3. Short bolts (x5).
4. Release the splash shield, pull it downwards and
align it. Tighten the bolts.
164. Fit the pulleys.

1. Water pump pulley
2. Fan pulley
165. Fit the alternator with the tensioning bracket.
166. Lay the drive belt in place.

1. Turn the belt tensioner bolt right back.
2. Lay the drive belt in place and tension it to
specification using the tensioning bolt.
New drivebelt:
Belt tension 578 ‐ 423 N
Deflection 4,5 mm
New drivebelt after 15 minutes running:
Deflection 5,5 mm
Used drivebelts:
3. Tighten the clamp bolt.
167. Lay the drivebelt in place (cont.).
1. Tighten the belt tensioner bolt.
2. Tighten the alternator mounting bolt.
168. Tighten the pulley bolts.
169. Fit the oil cooler.

Use a 13 mm hexagonal socket.
170. Insert the oil dipstick.
171. Connect the high‐pressure oil line to the vacuum
pump.
172. Connect the oil return line to the oil pump
housing.
173. Fit the oil filter.
174. Attach the engine lifting fixture.
175. Detach the engine from the assembly stand.

• Raise the engine with a workshop hoist.
• Detach the mounting bracket from the cylinder
block.
NOTE:
Right‐hand thread. Hold the pulley still when
fitting the fan.
176. Fit the fan with the viscous clutch.
Use the 32 mm open‐ended spanner.

Transit 1995 (08/1994-07/2000)
163 0)
Print

Special Tools

tightening
24‐003Remover, hose clamps
Proprietary Tools
Feeler gauge
Micrometer
Materials
Thread locking
270)
Bolt with 19 mm bolt
head
Super‐Plus 4 Coolant
ESD‐M97B‐49‐A
Concentrate
Remove
1. Standard preparatory measures
CAUTION:
WARNING:
Risk of scalding when the engine is hot.
Unscrew the lid of the coolant expansion tank.

2. Lift the vehicle.
4. Detach the front exhaust pipe.
1. Unscrew and remove the nuts.
2. Detach the bracket.

WARNING:

7. Detach the coolant hoses.
8. Remove the air intake hose.
9. Remove the oil filler cap.
10. Detach the exhaust gas recirculation (EGR) pipe

from the exhaust manifold.
11. Remove the inlet manifold bracket.
12. Remove the throttle linkage.

13. Disconnect the plug from the flame start glow plug
and detach the fuel line.
14. Remove the plenum chamber half.

Disconnect the plug.
CAUTION:
When releasing the fuel injection lines, hold
them with a suitable wrench.
CAUTION:
NOTE:
Remove the pipes in pairs.
16. Detach the fuel injection lines from the injectors.

17. Disconnect the leak‐off hoses.
18. Detach all the fuel injection lines from the fuel
injection pump.
20. Detach the coolant hose bracket (one bolt).
21. Detach the heater coolant hose and unclip it.

23. Unscrew and remove the upper retaining bolt of
the timing belt cover.
24. Remove the cylinder head cover.

NOTE:

• Mask the bores for the push rods.
NOTE:
26. Mark all the heads of the old cylinder head bolts
using a punch.
NOTE:
Slackening order.
Install
• Clean the mating faces on the cylinder head and
cylinder block.
• The cylinder head gasket is guided into place by the
locating sleeves.
The locating sleeves must engage in the head.
NOTE:
30. Pre‐tighten the cylinder head bolts in two stages
Insert the bolts and pre‐tighten them in two stages
in the indicated order.
31. Tighten the cylinder head bolts in a third stage.

NOTE:
tighten them by 90° using a socket wrench,
as the special tool cannot be used in these
positions.
Tighten the cylinder head bolts in the indicated
order.

• Fit the valve caps and push rods in the order in
• Fit the rocker shaft.
NOTE:
1. Five M10 bolts.

2. Four M8 bolts

1 and 6 ‐> 4 and 7
2 and 3 ‐> 5 and 8
4 and 7 ‐> 1 and 6
5 and 8 ‐> 2 and 3
Adjust the corresponding pair of valves in the
second column.
NOTE:
minimum torque. Renew the bolts(s) if
necessary.
using a socket wrench.
NOTE:
Renew it if necessary (it can be used again
several times).
NOTE:
Tightening order
36. Install the temperature gauge sender unit.

37. Screw in the upper retaining bolt of the timing belt
cover.
38. Fit the heater coolant hose and clip it into place.
39. Fit the coolant hose bracket.

41. Connect the fuel injection lines to the fuel injection
pump.
42. Install the temperature gauge sender unit and

attach the plug.
CAUTION:
the lines.
44. Connect the leak‐off hoses.
45. Install the plenum chamber half using a new

gasket.
46. Attach the EGR pipe to the exhaust manifold

using a new gasket.
47. Install the inlet manifold bracket.
48. Install the throttle linkage.

49. Attach the plug to the flame start glow plug and fit
the fuel line.
Adjust the EGR system

50. Make up a 20 mm gauge.
• Make up a gauge using a 19 mm bolt head and feeler
gauges.
• Check the required measurement of 20 mm using a
micrometer.
51. Insert the 20 mm gauge between the fuel injection

pump stop and the adjusting lever cam plate.
52. Insert a new 6 mm twist drill bit into the bore in

the throttle housing.
• If necessary, turn the throttle linkage until the twist
drill bit can be inserted in the bore.
• Tighten the lock nuts on the throttle linkage.
53. Check the setting of the EGR system.
54. Fit the oil filler cap.

55. Install the air intake hose.
56. Connect the coolant hoses to the thermostat

housing.
57. Lift the vehicle.
58. Install the front exhaust pipe with new gasket.

60. Install the lower engine cover.
• Check that the cables and the vacuum hoses are
routed correctly and if necessary secure them with
cable ties.
• Check the fluid levels and correct them if necessary.
gather data.
(visual check).
Print
Specifications
Engine Data
General
Identification code '95 model year 4GA
Identification code, vehicles up to 2,8 t '95 model year 4GC
'95 model year 4GB
vehicles)
Identification code, 2,5 TCI diesel engine '97 model year 4GD
'97 model year 4GE
vehicles)
Emission standard: 4GA A13
Emission standard: 4GC 93 EEC
Emission standard: 4GB 95/97 EEC
Emission standard: 4GD 96 EEC
Emission standard: 4GE 97 EEC
1‐2‐4‐3
front to rear)
Bore 93,67 mm
Stroke 90,54 mm
Power output (EEC) at rev/min 4000
Torque (EEC) 200 Nm
Torque (EEC) at rev/min 2100
Maximum permissible engine speed Intermittent rev/min 4400
Dimensions
Cylinder block Dimensions in mm
Bore diameter Class 1. 93,648 ‐ 93,660
Class 2. 93,660 ‐ 93,672
Class 3. 93,672 ‐ 93,684
Class 4. 93,684 ‐ 93,696
80 mm below cylinder
Measuring point
head mating face
Main bearing bore in the cylinder block ‐ rear Class A 81,00 ‐ 81,02
Class B 81,40 ‐ 81,42
Main bearing bore in the cylinder block ‐
Class A 74,00 ‐ 74,02
others
Class B 74,40 ‐ 74,42
Camshaft bearing bore in cylinder block Standard 61,000 ‐ 61,046
Oversize 61,500 ‐ 61,546
Pistons
Number of piston rings Compression rings 2
Oil scraper ring 1
Upper compression
Ring groove width 2,13 ‐ 2,15
ring
Lower compression
2,070 ‐ 2,095
ring
Oil scraper ring 4,030 ‐ 4,055
Piston pin bore: Orange 29,002 ‐ 29,006
Black 29,006 ‐ 29,010
Standard piston Ø Class 1. 93,621 ‐ 93,633
Class 2. 93,633 ‐ 93,645
Class 3. 93,645 ‐ 93,657
Class 4. 93,657 ‐ 93,669
Piston clearance in bore 0,015 ‐ 0,039
Height of measuring point for piston
clearance in bore, measured from the piston 81,5
crown at right angles to the piston pin bore
Piston oversize 0,65 and 1,00
Piston protrusion relative to cylinder block
0,201 ‐ 0,403
face at TDC, in production
Piston pins
Outside dia. Orange 28,996 ‐ 29,000
Outside dia. Black 29,000 ‐ 29,004
Piston pin length 79,000 ‐ 79,400
Clearance in piston pin bore (selective fit) 0,002 ‐ 0,010
Piston rings
Upper compression
Ring gaps: 0,40 ‐ 0,65
ring
Dimensions
Dimensions in mm
Lower compression
Ring gaps: 0,40 ‐ 0,65
ring
Upper compression
0,25 ‐ 0,50
ring
Lower compression
0,25 ‐ 0,50
ring
Upper compression
Ring widths: 2,313 ‐ 2,333
ring
Lower compression
1,975 ‐ 1,990
ring
Upper compression
Lateral clearance in grooves: 0,14 ‐ 0,172
ring
Lower compression
0,06 ‐ 0,092
ring
Dimensions
Connecting rods and big‐end bearings Dimensions in mm
Connecting rod length between bore centres: 1A 153,862 ‐ 153,931
2A 153,931 ‐ 154,000
3A 154,000 ‐ 154,069
4A 154,069 ‐ 154,138
Piston pin bush bore 29,010 ‐ 29,022
Piston pin clearance 0,006 ‐ 0,026
Big‐end bore without bearing shells 63,506 ‐ 63,520
Bearing shell oversizes 1,738 ‐ 1,729
0,125; 0,25; 0,375;
Bearing shell thickness (standard)
0,5
Bearing shell width 25,87 ‐ 26,13
Big‐end bearing clearance 0,030 ‐ 0,095
End float on big‐end bearing journal 0,140 ‐ 0,420
Max. ovality of big‐end bearing journal 0,025
when already re‐
Max. ovality of big‐end bearing journal 0,010
worked
Dimensions
Crankshaft and main bearings Dimensions in mm
Number of main bearing journals 5
Main bearing journal dia.: Rear Size 1 mm 76,980 ‐ 77,000
Size 2 mm 76,730 ‐ 76,750
Main bearing journal dia.: Others Size 1 mm 69,980 ‐ 70,000
Size 2 mm 69,730 ‐ 69,750
Regrind undersize (nominal, service
Size 3 mm 76,490 ‐ 76,500
diameter): ‐ Rear
Size 4 mm 69,490 ‐ 69,500
Regrind undersize (nominal, service
Size 3 mm 76,240 ‐ 76,250
diameter): Others
Size 4 mm 69,240 ‐ 69,250
Main bearing journal length (centre) 35,625 ‐ 35,675
Crankshaft end float 0,075 ‐ 0,325
Main bearing clearance: Nos. 1 to 4 0,052 ‐ 0,090
No. 5 0,056 ‐ 0,094
Number of teeth on driving gear and timing
Oil pump driving gear 32 teeth
belt pulley on crankshaft:
Timing belt pulley 24 teeth
Crankshaft on its own
Maximum turning torques: (without connecting 2,9 Nm
rods and pistons)
Crankshaft (with rear
oil seal, connecting
rods and pistons; 50 Nm
without cylinder head
and timing cover)
Camshaft Inlet 7,3
Exhaust 7,6
Number of bearings 5
Bearing journal diameter 55,966 ‐ 55,941
Bearing bore 56,032 ‐ 56,058
Bearing clearance 0,072 ‐ 0,116
Oversize bearings (outside diameter) 0,50
Camshaft end float 0,10 ‐ 0,25
Dimensions
Oil pump Dimensions in mm
Driving gear backlash 0,050 ‐ 0,330
Inner/outer rotor clearance 0,150 max.
Outer rotor/housing clearance 0,13 ‐ 0,30
Rotor end float 0,01 ‐ 0,09
New engine (idle
Oil pressure: 1,0 bar
speed)
Normal operation 2,7 ‐ 4,8 bar
Dimensions
Flywheel Dimensions in mm
Max. friction face run‐out 0,130 at radius of 120
Dimensions
Cylinder head Dimensions in mm
Valve guide length ‐ inlet and exhaust 56,50
Valve guide dia. ‐ inlet and exhaust: Outside dia. 14,738 ‐ 14,725
Inside dia. 8,982 ‐ 9,013
Valve guide protrusion relative to cylinder
1,80 ‐ 2,30
head cover mating face
Valve seat rings (when fitted), recess dia.: Inlet 43,50 ‐ 43,54
Exhaust 37,96 ‐ 38,00
Recess depth ‐ inlet and exhaust 9,00 ‐ 9,15
Valve seat angle relative to horizontal: Inlet 30° ‐ 30°30'
Exhaust 45° ‐ 45°30'
Valve head depth in cylinder head: Inlet 0,35 ‐ 0,65
Exhaust 0,50 ‐ 0,80
Recess dia. Inlet 43,50 max.
Exhaust 37,96 max.
Depth (both) 9,00 max.
Dimensions
Valves Dimensions in mm
Valve head dia. Inlet 41,90 ‐ 42,10
Exhaust 36,20 ‐ 36,40
Valve head seat angle: Inlet 29°30' ‐ 30°
Exhaust 44°30' ‐ 30°
Stem dia. Inlet 8,941 ‐ 8,966
Exhaust 8,923 ‐ 8,948
Stem clearance: Inlet 0,010 ‐ 0,066
Exhaust 0,024 ‐ 0,084
Valve spring identification colour Inlet Red
Exhaust Green and yellow
Dimensions
Rocker shaft and rocker arms Dimensions in mm
Rocker shaft diameter 18,87 ‐ 18,90
Number of springs on rocker shaft 4
Spring length (compressed) 25,4
Spring force (compressed) 17 ‐ 21 N
Rocker arm clearance on shaft 0,02 ‐ 0,08
Dimensions
Push rods and tappets
Push rod length 154,87 ‐ 153,87
Push rod dia. 7,72 ‐ 8,03
Tappet stem dia. 17,475 ‐ 17,488
66,10 ‐ 66,85
Dimensions
Valve timing and valve clearance Dimensions in mm
Nominal valve timings with clearance of 0,5
Inlet valve opens 5° before TDC
mm:
Inlet valve closes 27° after BDC
Exhaust valve opens 57° before TDC
Exhaust valve closes 7° after TDC
Valve lift: Inlet 9,12
Exhaust 10,81
Valve clearance (warm or cold): Inlet 0,20
Exhaust 0,38
Dimensions
Drive belt tension, alternator, coolant
pump, crankshaft, fan
New belt Belt tension: 578 ‐ 423 N
Deflection: 4,5 mm
New belt after 15 minutes' running Belt tension: 378 ‐ 423 N
Deflection: 5,5 mm
Used belt (used for less than 10 minutes) 378 ‐ 423 N
Paint mark at three points Green
Dimensions
V‐belt tension, power steering Measurement in N
New belt 578 ‐ 623
New belt after 15 minutes' running 378 ‐ 423
Used belt 378 ‐ 423
Paint mark at three points Green
Main bearing shell thickness ‐ in production
Colour of build Size class Bearings Bearing shell Bearing shell
data plate identification thickness in mm
colour
Blue 1A Rear Red 1,972 ‐ 1,963
Blue 1,982 ‐ 1,973
Others Red 1,974 ‐ 1,965
Blue 1,984 ‐ 1,975
Gold 2A Rear Red/white 2,097 ‐ 2,088
Orange/blue 2,107 ‐ 2,098
Others Red/white 2,099 ‐ 2,090
Orange/blue 2,109 ‐ 2,100
Red 2B Rear White 2,297 ‐ 2,288
Orange 2,307 ‐ 2,298
Others White 2,290 ‐ 2,295
Orange 2,309 ‐ 2,300
Service main bearing shells (in sets)
Cylinder block size Crankshaft size Size Bearing shell colour
code
A 1 1A Top red Bottom blue
2; re‐ground 2A One class No colour
B 1 1B One class No colour
Top white Bottom
2; re‐ground 2B
orange
3; re‐ground 3B One class No colour
4; re‐ground 4B One class No colour
Big‐end bearing shells ‐ available for following crankshaft sizes
Size Big‐end bearing journal dia. in Bearing shell thickness in mm
mm
1 60,00 1,729
2 59,75 1,854
3 59,50 1,988
4 59,25 2,113
Description Ford
Specification
Grease for input shaft splines and sliding face of clutch release bearing on
ESDM‐1C220‐A
guide sleeve
Grease for timing belt tensioner mounting face SM1C‐4515‐A
Sealer ‐ non‐hardening ‐ Hylomar PL32M SPM‐4G‐9112‐F
Capacity
Description Litres
Engine oil ‐ initial fill incl. filter 7
Engine oil ‐ oil change incl. filter change 6
Coolant 11,6
Engine oil
Viscosity / Ambient Designation Specification
temperature
SAE 10W40 / ‐20 to over 40 Ford XR+ High‐performance ACEA A3‐96/B3‐96
degrees Centigrade High‐lubricity Engine Oil or API/SH/CD EC
NOTE:
Torques
General Nm lbf.ft
Lock panel to radiator 11 8
Torques
Front exhaust pipe to rear exhaust pipe 38 28
Torques
Drive belt tensioning bracket 23 17
Torques
Steering Nm lbf.ft
Torques
EGR cooler bracket 23 17
EGR cooler 23 17
Torques
Torques
Fuel System Nm lbf.ft
Fuel filter 17 12
Torques
Gear lever to transmission housing 25 19
Starter motor earth lead to transmission flange 35 26
Torques
Allen screws ‐ rear oil seal housing 14 10
Flywheel to crankshaft ‐ Stage 1 21 15
Flywheel to crankshaft ‐ Stage 2 30° 30°
Torques
Bolt ‐ injector retaining plate 40 30
Bracket for supporting engine lifting bracket 23 17
Engine Assembly ‐ Remove and Install

Transit 1995 (08/1994-07/2000)
(21 134 0)
Print

Special Tools
21‐138 AEngine lifting bracket
21‐138‐01Adaptor for 21‐138
coolant hose clip
Workshop Equipment
Bracket to support the
Finis code 6 181 596
engine lifting bracket
Transmission jack
Workshop hoist
Materials
Cable ties
Thread‐locking
270)
High temperature
ESD‐M1C220‐A
grease
Driveshaft pilot
Finis code 1042972
bearing
Coolant concentrate
ESD‐M97B‐49A
Super‐Plus 4
Remove
CAUTION:
WARNING:

3. Remove the engine undershield.
WARNING:
6. Detach the hood.
7. Pull out the plug of the engine coolant temperature

sensor (ECT sensor).
8. Remove the engine lifting eye and attach the
bracket for supporting the engine lifting bracket.
9. Disconnect the coolant hoses.
10. Disconnect the vent hose.

2,5 turbocharged diesel engine only

11. Remove the vent hose.
2,5 TCI diesel engine only

12. Disconnect the vent hose and vacuum hoses.
CAUTION:
Do not remove the radiator grille at this
stage on vehicles with a headlamp washer
system. Refer to the next step.
13. Detach the radiator grille (two bolts) and unclip it
on both sides.
14. Disconnect the hose connector for the headlamp

washer hose at the radiator grille (when applicable).
15. Remove the radiator grille.
16. Detach the hood lock operating cable.

1. Remove the three bolts.
2. Unclip the cable and lay it to the side.
18. Disconnect the lower coolant hose.

19. Disconnect the intercooler hose from the
turbocharger.
20. Detach the support brace from the crossmember.

22. Detach the front bumper (six bolts).

23. Disconnect the air intake hose and pull out the
plug of the intake air temperature sensor (IAT sensor).
24. Detach the hood lock panel together with the
radiator.
The radiator has a push‐fit at the bottom.
CAUTION:
Close off the openings.
25. Remove the turbocharger air intake hose.

2. Hose clip on air cleaner.
3. Hose clip on turbocharger.

26. Disconnect the vacuum hoses.
1. From the throttle body to the manifold absolute
pressure sensor (MAP sensor).
2. From the throttle control diaphragm unit to the
current to vacuum transducer (CVT).

27. Disconnect the hoses.
1. Coolant hose
2. Front hose from the oil cooler
28. Detach the power steering pump with the
mounting bracket.
1. Remove the clamp bolt.
2. Unscrew the mounting bolt.
3. Remove the V‐belt.
Suspend the power steering pump to one side.

29. Remove the coolant hose.
31. Remove the EGR pipe.

Remove the gasket.

32. Disconnect the coolant hoses and pull out the plug
of the throttle position sensor (TP sensor).
33. Disconnect the vacuum hose and the plug from the
exhaust gas recirculation (EGR) valve.
34. Pull out the plug of the flame start glow plug.
35. Detach the wiring loom bracket from the inlet
manifold.
36. Disconnect the fuel injection pump plug.

Pull the latch of the plug on the fuel injection pump
towards the rear, turn the plug in the direction of the
arrow and pull it off.
Close the connection on the fuel injection pump with
the red cleaned cover.
37. Disconnect the fuel line from the flame start glow
plug.
38. Remove the EGR cooler.
2,5 turbocharged diesel engine

NOTE:
Do not lose the seals.
39. Detach the heater hoses from the bulkhead.

Compress the collar of the plastic insert and pull off
the hose using angled pointed pliers.
40. Disconnect the plug from the crankshaft position
sensor (CKP sensor).
41. Remove the starter motor.

• Cut the cable ties.
• Remove the bolts.
42. Detach the vacuum pump vacuum pipe.

43. Disconnect the alternator.
44. Disconnect the engine main wiring loom.

Cut the cable ties.
1. Remove the cover.
2. Pull the latch towards the rear, turn the multiplug in
the direction of the arrow and pull it off.
• Disconnect the multiplug.
45. Disconnect the fuel lines.

1. Separate the line from the fuel filter.
2. Pull off the leak‐off return line from the injector.
46. Detach the clamping bracket of the steering
intermediate shaft.

48. Detach the steering gear.
Pull the steering gear forwards slightly and lower it
as far as possible.
49. Remove the transmission cover.
50. Detach the front cover of the clutch housing.
51. Detach the front exhaust pipe and catalytic

converter from the exhaust manifold.
1. Unscrew the nuts.
2. Detach the mounting.
CAUTION:
Overstretching the flexible pipe can cause
damage.
52. Detach the front exhaust pipe from the rear
exhaust pipe.
Unscrew the nuts and unhook the exhaust.
53. Detach the clutch housing lower cover.

Two expanding pins on each side.
54. Detach the clutch housing upper cover.

Remove one expanding pin on each side.
55. Unlock and disconnect the reversing lamp plug.
56. Disconnect the fuel feed line from the fuel pump.
57. Detach the clutch cable.

58. Detach the fuel line bracket.
59. Unscrew the flange bolts.

1. Unscrew the five flange bolts.
2. Bolts of the left and right‐hand engine mounting
brackets.
Support the transmission with a suitable block of
wood on the crossmember.
60. Detach both engine mountings.
61. Unscrew the two bolts on the left and right‐hand

engine mounting brackets.

NOTE:
Use the front mounting tab of the adaptor.
63. Fit the engine lifting bracket.

64. Raise the engine slightly.
65. Remove the right‐hand bracket with the engine
mounting.
66. Remove the left‐hand bracket with the engine
mounting.
67. Carefully lift the engine out of the engine

compartment with the workshop hoist.
Install
68. General notes.
• Before screwing them in, coat the threads of the
bolts with thread‐locking compound (SDM‐4G‐9107‐A)
• Always renew self‐locking nuts.
CAUTION:
Use a new driveshaft pilot bearing.

• Clean the internal splines of the clutch disc, the
splines of the transmission input shaft and the guide
sleeve of the clutch release bearing.
• Thinly apply high‐temperature grease (ESDM‐1C220
A) to the transmission input shaft, clutch release
bearing guide sleeve, driveshaft pilot bearing and the
clutch splines.
70. Locate the engine in position.
Secure the engine to the transmission with two
flange bolts on opposite sides.
NOTE:
Do not tighten.
71. Install the left‐hand bracket with the engine

mounting (three bolts).
NOTE:
Do not tighten.
72. Install the right‐hand bracket with the engine

mounting (three bolts).
Remove the block of wood from between the
transmission and the crossmember.
73. Detach the engine lifting bracket.
75. Tighten the five flange bolts.
76. Fit the fuel line bracket.
77. Align the engine centrally in the slots.
78. Tighten the bolts of the left and right‐hand engine

mounting brackets.
If necessary, raise the transmission slightly with the
transmission jack.
79. Tighten the bolts of the left and right‐hand engine

mounting brackets.
80. Tighten the engine mounting nuts.
81. Fit the clutch housing front cover.
82. Attach the clutch cable.
83. Connect the fuel feed line to the fuel pump.
84. Connect the reversing lamp plug.

85. Fit the clutch housing upper cover.
One expanding pin on each side.
86. Fit the clutch housing lower cover.
Two expanding pins on each side.
CAUTION:
Overstretching the flexible pipe can cause
damage.
87. Connect the front exhaust pipe to the rear exhaust
pipe using a new gasket.
Hook the front exhaust pipe in place and tighten the
nuts.
88. Connect the front exhaust pipe using a new

gasket.
89. Attach the transmission cover.
90. Fit the steering gear.

92. Attach the clamping bracket of the steering
intermediate shaft.
NOTE:
Ground cable.
93. Install the starter motor.

• Secure the wiring looms with cable ties.
94. Connect the fuel lines.

1. To the fuel filter.
2. Leak‐off return line to the rear injector.

95. Connect the heater coolant hoses at the bulkhead.
96. Attach the vacuum pump vacuum pipe.

97. Connect the alternator.
98. Connect the engine main wiring loom.
1. Screw on the multiplug as far as it will go.
• Connect the multiplug.
2. Clip the cover in place.
Secure the main wiring loom with a cable tie.
99. Push on the CKP sensor connector.
100. Fit the EGR cooler using a new gasket.

101. Attach the coolant hoses and connect the plug of
the TP sensor.
102. Fit the EGR pipe with a new gasket.

103. Connect the coolant hose.
105. Connect the plugs.

• Remove the red blanking cover from the fuel
injection pump.
• Screw on the fuel injection pump plug as far as it will
go.
106. Connect the fuel line of the flame start glow plug.
107. Connect the vacuum hose and the plug to the

EGR valve.
108. Connect the plug of the flame start glow plug.
109. Fit the wiring loom bracket to the inlet manifold.

110. Connect the vacuum hoses.
1. From the throttle body to the MAP sensor.
2. From the throttle control diaphragm unit to the CVT
sensor.
111. Connect the turbocharger air intake hose.

2. To the air cleaner.
3. To the turbocharger.

112. Connect the hoses.
1. Front hose from the oil cooler
2. Coolant hose
113. Fit the power steering pump with the mounting

bracket.
Install the bolts with the nuts.
1. Fit the V‐belt.
2. Tension the V‐belt and tighten the clamp bolt.
3. Tighten the mounting bolt.

114. Fit the hood lock panel together with the radiator.
The radiator has a push‐fit at the bottom.

116. Connect the support brace to the crossmember.
117. Connect the intercooler hose to the turbocharger.
118. Connect the lower coolant hose.


120. Attach the hood lock operating cable.
1. Clip the cable in place.
2. Three bolts.

121. Attach the air intake hose and connect the plug
of the IAT sensor.
122. Fit the front bumper (six bolts).

Cover the bolts with caps.
123. Locate the radiator grille in position.
124. Connect the hose connector for the headlamp
washer hose at the radiator grille (when applicable).
125. Clip the radiator grille in place on both sides and

attach it.

126. Connect the vent hose and vacuum hoses.

127. Connect the vent hose.
128. Connect the vent hose to the radiator.

129. Connect the coolant hoses.
130. Remove the bracket for supporting the engine

lifting bracket and fit the engine lifting eye.
131. Connect the plug of the ECT sensor.
132. Fit the hood.

• Close the hood and check the alignment.
• Open the hood and align if necessary.

• Check that the cables, hoses and lines are routed
correctly and, if necessary, secure them with cable
ties.
• Set the clock.
• Check the fluid levels, correct if necessary.
collect data.
(visual check).

Transit 1995 (08/1994-07/2000)
163 0)
Print

Special Tools

tightening
coolant hose clip
Materials
Sealer (Hylomar
SPM‐4G‐9112‐F
PL32M)
Thread‐locking
270)
Coolant concentrate
ESD‐M97B‐49A
Super‐Plus 4
Remove
CAUTION:
WARNING:

4. Detach the front exhaust pipe bracket.

WARNING:


8. Remove the vent hose.

9. Disconnect the vent hose and the vacuum hoses.

10. Disconnect the air intake hose and pull out the
plug of the intake air temperature sensor (IAT
sensor).
CAUTION:

3. Release the hose clip on the turbocharger.
EGR valve.
manifold.

14. Remove the coolant hose.

17. Disconnect the coolant hoses and pull out the plug
of the throttle position sensor (TP sensor).
19. Disconnect the plug of the flame start glow plug

1. Release the lock and pull off the fuel line.
2. Plug of flame start glow plug.
3. Plug of engine coolant temperature sensor (ECT
sensor).

20. Detach the following parts:
1. Connecting hose for the manifold absolute pressure
sensor (MAP sensor).
2. Detach the power steering reservoir and lay it to
one side.
3. Plug of air charge temperature sensor (ACT
sensor).

21. Detach the upper section of the air cleaner housing
(four clips).

22. Detach the lower section of the air cleaner
housing.
1. Detach the heat shield.
2. Remove the air cleaner element.
3. Unscrew the nut.

housing (continued).
1. Detach the housing from the stud and pin.
2. Lift the rear part and pull out the intake from under
the power steering hose.
NOTE:
The fuel pump heat shield is left in position.
24. Detach the exhaust manifold bracket from the

cylinder block.
25. Detach the exhaust manifold (eight bolts) and
swivel it to one side.
CAUTION:
Hold with a suitable wrench while releasing
the fuel injection lines.
CAUTION:

1. Disconnect and remove the rear fuel injection lines
as a pair.
2. Disconnect and remove the front fuel injection lines
as a pair.
27. Pull off the leak‐off hoses from the injectors.
28. Detach the fuel filter and place to one side.

30. Unscrew the upper bolt of the timing belt cover.
NOTE:
32. Detach the rocker shaft.

• Seal off the holes for the push rods.
NOTE:
The cylinder head bolts must not be used
more than three times. If a bolt already has
two punch marks, it should be renewed.
NOTE:
Slackening sequence.
Install
Clean the mating faces of the cylinder head and
cylinder block.
The cylinder head gasket is guided by the locating
sleeves.
The locating sleeves must engage in the cylinder
head.
NOTE:
The cylinder head bolts can be used a
maximum of three times. If two punch
marks are already present, renew the bolt.
38. Tighten the cylinder head bolts, stages 1 and 2.
Insert the bolts and tighten them in two stages in
the indicated order.
NOTE:
tighten them through 90° using a socket, as
the special tool cannot be used at these
points.
39. Tighten the cylinder head bolts, stage 3.
Tighten the cylinder head bolts in the specified
order.

• Refit the valve caps and push rods in the order in
NOTE:
1. Five M10 bolts.

2. Four M8 bolts.

• Turn the crankshaft until the pairs of valves indicated
1 and 6 ‐> 4 and 7
2 and 3 ‐> 5 and 8
4 and 7 ‐> 1 and 6
5 and 8 ‐> 2 and 3
Adjust the corresponding pairs of valves in the
second column (see step ).
NOTE:
specified minimum torque. Renew the bolt(s)
if necessary.
using a socket.
2. Clearance for exhaust valves: 0,38 mm
3. Clearance for inlet valves: 0,20 mm
the valve cap and rocker arm.
NOTE:
several times).
NOTE:
Tightening order
44. Fit the temperature gauge sender unit.

45. Screw in the upper bolt of the timing belt cover.
CAUTION:
3. Connect the leak‐off hoses.
CAUTION:
47. Connect the fuel injection lines to the fuel
injection pump.
49. Apply sealer (SPM‐4G‐9112‐F) to the mating face

of the exhaust manifold flange (2,5 turbocharged
diesel engine shown).
NOTE:
Use thread‐locking compound (SDM‐4G‐9107
A).
50. Fit the exhaust manifold to the cylinder head
(eight bolts).
51. Fit the exhaust manifold bracket, together with the

fuel pump heat shield, to the cylinder block.

52. Guide in the lower section of the air cleaner
housing, rear part first.

53. Fit the lower section of the air cleaner housing.
1. Guide the intake through under the power steering
hose.
2. Locate the housing on the stud and pin.
3. Tighten the retaining nut.
4. Fit the air cleaner element.
5. Fit the heat shield.

54. Fit the upper section of the air cleaner housing
(four clips).

55. Fit the following parts:
1. Connect the MAP sensor connecting hose.
2. Attach the power steering reservoir.
3. Connect the ACT sensor plug.
56. Connect the plug of the flame start glow plug and
attach the fuel line.
1. Fuel line to flame start glow plug.
3. Plug of ECT sensor.

58. Attach the coolant hoses and connect the plug of
the TP sensor.

60. Fit the coolant hose.
62. Connect the vacuum hose and plug to the EGR
valve.



65. Attach the air intake hose and connect the plug of
the IAT sensor.


68. Fit the front exhaust pipe bracket.

ties.
• Set the clock.
gather data.
(visual check).
Print
Specifications
Engine Data
General
Identification code '95 model year 4EB
Identification code '97 model year 4EC
Emission standard: 4EB 95 EEC
Emission standard: 4EC 97 EEC
1‐2‐4‐3
front to rear)
Bore mm 90,54
Stroke mm 93,67
Cubic capacity cm3 2496
Power output (EEC) kW 74
Power output (EEC) (PS) 100
at rev/min 4000
Torque (EEC) Nm 224
at rev/min 2100
Intermittent rev/min 4400
 1. Production date
 2. Engine code
 2.5 turbocharged diesel engine (100 PS): 4EB
 3. Engine serial number
Dimensions
Note
Dimensions: See Technical Data on the 2.5 turbocharged diesel
engine (85 PS)
Description Ford
Specification
High‐temperature grease for input shaft splines and for sliding surface of
ESDM‐1C220‐A
clutch release bearing on guide sleeve
Grease for mounting face of timing belt tensioner SM1C‐4515‐A
Sealer, non‐hardening ‐ Hylomar PL32M SPM‐4G‐9112‐F
High‐temperature grease ESD‐M1C‐220‐A
Coolant concentrate Super‐Plus 4 ESD‐M97B‐49‐A
Capacity
Description Litres
Engine oil ‐ oil change with filter change 6
Coolant 11,5
Engine oil
Viscosity/Ambient Designation Specification
temperature
SAE 10W30 / ‐20 to over 40°C
Oil 96/B3‐96 or API/SH/CD EC
Ford Formula S Synthetic ACEA A3‐96/B3‐96 or
Engine Oil API/SH/CD EC
Ford XR+ High‐performance ACEA A3‐96/B3‐96 or
SAE 10W40 / ‐20 to over 40°C
High‐lubricity Engine Oil API/SH/CD EC
SAE 15W40 / ‐15 to over 40°C
Oil 96/B3‐96 or API/SG/CD
NOTE:
Torques
General Nm lbf.ft
Hose clips in general 3 2
Lock panel to radiator 11 8
Torques
Inlet manifold Nm lbf.ft
Inlet manifold to cylinder head 23 17
Torques
Exhaust manifold studs 23 17
Front exhaust pipe bracket 24 18
Torques
Alternator bracket 19 14
Alternator clamp bolt 24 18
Torques
Driveshaft centre bearing to floor pan 33 24
Gearshift lever to transmission housing 25 19
Fuel lines bracket to transmission flange 35 26
Nut of rear transmission mounting to transmission 50 37
Starter motor earth lead to transmission flange 35 26
Torques
Water pump pulley 10 7
Fan pulley 10 7
Coolant drain plug 23 17
Engine coolant temperature sensor (ECT sensor) 13 10
Torques
Steering Nm lbf.ft
Power steering pump mounting bolt 23 17
Drive belt clamp bolt 23 17
Torques
Oil pressure regulating valve 56 41
Oil pump to adaptor plate 19 14
Oil pump housing to cylinder block 19 14
Oil pump housing retaining plate 23 17
Sump to cylinder block 14 10
Oil cooler 70 52
Vacuum pump oil pressure pipe 21 15
Torques
Torques
Torques
Fuel system Nm lbf.ft
Fuel pump to cylinder block 23 17
Fuel injection pump to adaptor plate 23 17
Fuel injection pump rear bracket 23 17
Fuel line to fuel injection pump 18 13
Fuel filter 17 12
Fuel injection pump timing belt pulley 25 19
Torques
Turbocharger Nm lbf.ft
Turbocharger to exhaust manifold 23 17
Air intake pipe to throttle body 23 17
Throttle assembly to exhaust manifold 23 17
Intermediate exhaust manifold to turbocharger 23 17
Oil drain pipe to connector 23 17
Torques
Camshaft rear cover plate to cylinder block 23 17
Front retaining/pressure plate to cylinder block 23 17
Cylinder head to cylinder block ‐ stage 1 70 52
Cylinder head to cylinder block ‐ stage 2 70 52
Cylinder head to cylinder block ‐ stage 3 90° 90°
Engine adaptor plate to cylinder block ‐ bolts 1 ‐ 8 36 27
Engine adaptor plate to cylinder block ‐ bolt 9 23 17
Starter motor to cylinder block 35 26
Hexagon socket head bolts of rear oil seal housing 14 10
Camshaft timing pulley ‐ stage 1 10 7
Camshaft timing pulley ‐ stage 2 160 118
Big‐end bearing caps ‐ stage 1 56 41
Big‐end bearing caps ‐ stage 2 69 51
Crankshaft main bearing caps ‐ stage 1 84 62
Crankshaft main bearing caps ‐ stage 2 120 89
Bolt of crankshaft pulley/vibration damper 163 12
Flywheel to crankshaft ‐ stage 1 21 15
Flywheel to crankshaft ‐ stage 2 30° 30°
Timing belt cover to intermediate plate 7 5
Splash shield to timing belt cover 1 0,7
Clamp bolt of timing belt tensioner 24 18
Tensioning pulley bolt 58 43
Water pump to intermediate plate M8 23 17
Water pump to intermediate plate M10 46 34
Timing case cover to intermediate plate 23 17
Engine adaptor plate bracket (bolts) 46 34
Engine adaptor plate bracket (bolt and nut) 23 17
Flywheel immobilising tool to cylinder block 35 26
Torques
Cylinder head cover ‐ stage 1 7 5
Cylinder head cover ‐ stage 2 7 5
Bolt for injector retaining plate 40 29
Thermostat housing bolts 23 17
EGR valve to throttle housing 18 13
Bypass hose to cylinder head 18 13
Mounting bracket for engine lifting bracket 23 17

Transit 1995 (08/1994-07/2000)
163 0)
Print

Special Tools

tightening
coolant hose clips
Materials
Coolant concentrate
ESD‐M97B‐49A
Super‐Plus 4
Sealer (Hylomar
SPM‐4G‐9112‐F
PL32M)
Thread‐locking
270)
Proprietary Tools
Feeler gauge
Remove
CAUTION:
WARNING:
Unscrew the cap from the coolant expansion tank.

4. Disconnect the air intake hose from the
turbocharger.

WARNING:
Risk of scalding when the engine is warm.

Unscrew the cap of the coolant expansion tank.
8. Disconnect the coolant hoses.

Use Special Tool 24‐003 if required.
9. Disconnect the plugs.
1. From the engine coolant temperature sensor (ECT
sensor).
2. From the temperature gauge sender unit.
10. Disconnect the turbocharger air intake hose to
the air cleaner.
11. Remove the air intake pipe.

12. Pull out the plug from the exhaust gas recirculation
valve (EGR valve).
13. Pull out the plug from the flame start glow plug
and disconnect the fuel pipe.
manifold.
15. Detach the following parts:

1. Connecting hose for the manifold absolute
pressure sensor (MAP sensor).
2. Detach the brake fluid reservoir and lay it to one
side.
3. Plug of air charge temperature sensor (ACT
sensor).
16. Detach the upper section of the air cleaner
housing (four clips).

housing.
1. Release the heat shield.
2. Remove the air cleaner element.
3. Unscrew the retaining nut.

housing (continued).
1. Release the housing from the stud and the pin.
2. Lift the rear part and withdraw the intake from
under the power steering hose.
19. Unscrew the eight exhaust manifold bolts.
20. Suspend the exhaust manifold with the

turbocharger to one side.
21. Disconnect the heater coolant hose.
Unclip the hose and lay it to one side.
22. Detach the fuel injection line retaining clamp.
1. Press a screwdriver blade between the fuel
injection line and the rubber insulator.
2. Prise off the cover of the retaining clamp.
Remove the lower part of the retaining clamp.
CAUTION:
Hold with a suitable wrench when releasing
CAUTION:
Close all the connections with dust caps.
1. Disconnect the rear fuel injection lines as a pair

and remove them.
2. Disconnect the front fuel injection lines as a pair
and remove them.
24. Disconnect the leak‐off hoses and the leak‐off

return hose from the injectors.

NOTE:

• Mask the holes for the push rods.
NOTE:
Cylinder head bolts must not be used more
30. Mark the heads of all the reused cylinder head
bolts with a punch mark.
NOTE:
Slackening order.
Install
NOTE:
Do not damage the mating faces.

cylinder block.
The cylinder head gasket is positioned with the
locating sleeves.
head.
NOTE:
Cylinder head bolts must not be used more
punch marks, it must be renewed.
35. Tighten the cylinder head bolts (stages 1 and 2).
• Lightly oil the threads and contact faces of the
• Insert the bolts and tighten them in two stages in
NOTE:
tighten them through 90° with a wrench as
points.
36. Tighten the cylinder head bolts (stage 3).
order.

• Fit the valve caps and push rods in the order in
NOTE:
1. Five M10 bolts.

2. Four M8 bolts

1 and 6 ‐> 4 and 7
2 and 3 ‐> 5 and 8
4 and 7 ‐> 1 and 6
5 and 8 ‐> 2 and 3
Adjust the corresponding pair of valves indicated in
the second column (see step ).
NOTE:
necessary.
using a wrench.
NOTE:
several times).
NOTE:
Tightening order.
40. Install the cylinder head cover.
41. Connect the fuel injection lines to the injectors

and the fuel injection pump.
Remove the dust caps.
CAUTION:
Hold with a wrench while securing the fuel
injection lines.
42. Fit the fuel injection line retaining clamp.
43. Compress the fuel injection line retaining clamp.
44. Fit the coolant temperature gauge sender unit.

47. Connect the leak‐off hoses and leak‐off return

hose to the injectors.
48. Connect the heater coolant hose and clip it in
place.
49. Coat the mating face of the exhaust manifold

flange with sealer (SPM‐4G‐9112‐F).
NOTE:
Use thread‐locking compound (SDM‐4G‐
9107‐A).
50. Attach the exhaust manifold to the cylinder head
using a new gasket (eight bolts).
51. Guide in the lower section of the air cleaner

housing, rear part first.
52. Secure the lower section of the air cleaner
housing.
1. Guide the intake through under the power steering
hose.
2. Locate the lower section on the stud and pin.
3. Tighten the retaining nut.
4. Fit the air cleaner element.
5. Fit the heat shield.
53. Fit the upper section of the air cleaner housing

(four clips).
54. Fit the following parts:

1. Connecting hose of MAP sensor.
2. Brake fluid reservoir.
3. Plug of ACT sensor.
55. Connect the plug to the flame start glow plug and
56. Attach the wiring loom bracket to the inlet
manifold.
57. Connect the plug to the EGR valve.
58. Fit the air intake pipe with a new gasket.
59. Connect the air intake hose.


61. Fit the air intake hose to the turbocharger.

65. Connect the plugs.
1. ECT sensor.
2. Temperature gauge sender unit.

• Check the routing of the wiring and vacuum hoses
and secure with cable ties where necessary.
• Reprogramme the preset radio stations.
• Check the fluid levels and correct as necessary.
collect data.
(visual inspection).
Print
Specifications
Engine Data
General
4ED
vehicles)
Emission standard 97 EEC
1‐2‐4‐3
front to rear)
Bore 93,67 mm
Stroke 90,54 mm
at rev/min 4000
Torque (EEC) 256 Nm
at rev/min 2100
Idle speed rev/min 850 ± 25
Highest permissible engine speed ‐ duration rev/min 4000
Permissible engine speed ‐ short‐period rev/min 4400
Dimensions
Note
Dimensions: refer to General Specifications ‐ 2.5 Turbocharged Diesel Engine (85 PS)
Description Ford
Specification
Grease for input shaft splines and sliding face of clutch release bearing on
ESDM‐1C220‐A
guide sleeve
Grease for timing belt tensioner mounting face SM1C‐4515‐A
Sealer ‐ non‐hardening ‐ Hylomar PL32M SPM‐4G‐9112‐F
Capacity
Description Litres
Engine oil, oil change excl. filter 5,75
Engine oil ‐ oil change incl. filter change 6
Coolant 11,6
Engine oil
Viscosity/Ambient Designation Specification
temperature
SAE 10W40 / ‐20 to over 40 Ford XR+ High‐performance ACEA A3‐96/B3‐96 or
degrees Centigrade High‐lubricity Engine Oil API/SH/CD EC
SAE 5W30 / ‐20 to over 10 Ford Formula E Economy ACEA A1‐96/B1‐96 and WSS‐
degrees Centigrade Engine Oil M2C912‐A1
NOTE:
Torques
General Nm lbf.ft
Torques
Exhaust system Nm lbf.ft
Front exhaust pipe to rear exhaust pipe 38 28
Exhaust manifold bracket with fuel pump heat shield 23 17
Torques
Power steering pump Nm lbf.ft
Clamp bolt 23 17
Mounting bolt 23 17
Torques
Steering Nm lbf.ft
Torques
Exhaust gas recirculation Nm lbf.ft
EGR cooler 23 17
Torques
Torques
Fuel System Nm lbf.ft
Fuel filter 17 13
Torques
Gear lever to transmission housing 25 18
Torques
Torques
Bolt ‐ injector retaining plate 40 30
Thermostat housing 23 17
Bracket for supporting engine lifting bracket 23 17

Transit 1995 (08/1994-07/2000)
163 0)
Print

Special Tools

tightening
coolant hose clip
Materials
Thread‐locking
270)
Coolant concentrate
ESD‐M97B‐49A
Super‐Plus 4
Remove
CAUTION:
WARNING:
Danger of scalding if the engine is warm.


WARNING:
Danger of scalding if the engine is warm.

8. Pull off the vacuum hoses.
9. Disconnect the air intake hose and pull out the plug
of the intake air temperature sensor (IAT sensor).
CAUTION:

3. Release the hose clip on the turbocharger.
EGR valve.
manifold.

Remove the gasket.
14. Detach the coolant hose.
16. Disconnect the plug of the flame start glow plug

1. Release the lock and pull off the fuel line.
3. Plug of engine coolant temperature sensor (ECT
sensor).
NOTE:
The fuel pump heat shield is left in position.
17. Detach the exhaust manifold bracket from the

cylinder block.
18. Detach the exhaust manifold (eight bolts) and

swivel it to one side.
CAUTION:
Hold with a wrench while releasing the lines.
19. Detach the injection pipes from the injectors.

CAUTION:
1. Pull off the fuel leak off hoses.

2. Remove the injector lines.
CAUTION:
20. Detach the injection pipes from the injection

pump.
21. Detach the fuel filter and place to one side.


NOTE:
25. Detach the rocker shaft.

• Seal off the holes for the push rods.
NOTE:
NOTE:
Slackening sequence.
Install
cylinder block.
The cylinder head gasket is guided by the locating
sleeves.
head.
NOTE:
31. Tighten the cylinder head bolts, stages 1 and 2.
Insert the bolts and tighten them in two stages in
NOTE:
tighten them through 90° using a socket, as
points.
32. Tighten the cylinder head bolts, stage 3.
order.

• Refit the valve caps and push rods in the order in
NOTE:
1. Five M10 bolts.

2. Four M8 bolts.

• Turn the crankshaft until the pairs of valves indicated
1 and 6 ‐> 4 and 7
2 and 3 ‐> 5 and 8
4 and 7 ‐> 1 and 6
5 and 8 ‐> 2 and 3
Adjust the corresponding valve pair in the second
column (see previous step).
NOTE:
specified minimum torque. Renew the bolt(s)
if necessary.
using a socket.
2. Clearance for exhaust valves: 0,38 mm
3. Clearance for inlet valves: 0,20 mm
the valve cap and rocker arm.
NOTE:
Tightening order
NOTE:
several times).
37. Fit the temperature gauge sender unit.

39. Connect the fuel injection lines to the fuel injection

pump.
CAUTION:
Hold with a wrench while securing the lines.
40. Connect the fuel injection lines to the injectors and

the fuel injection pump.
1. Push on the fuel leak off lines.
2. Install the injector lines.
NOTE:
Use thread‐locking compound (SDM‐4G‐9107
A).
42. Attach the exhaust manifold with a new seal to the
cylinder head (eight bolts).
43. Fit the exhaust manifold bracket, together with the

fuel pump heat shield, to the cylinder block.
44. Connect the plug of the flame start glow plug and
1. Fuel line to flame start glow plug.
3. Plug of ECT sensor.

46. Attach the coolant hose.
48. Connect the vacuum hose and plug to the EGR

valve.


51. Attach the air intake hose and connect the plug of
the IAT sensor.
52. Connect the vacuum hoses.

If necessary, use Special Tool 24‐003.


ties.
• Set the clock.
gather data.
(visual check).

TRANSIT

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General Specifications Transit 1995 (08/1994-07/2000)

Description and Operation Transit 1995 (08/1994-07/2000)

Description and Operation

Modified parts from MY '95 onwards

4. Cylinder head gasket.

5. Inlet manifold gasket.

6. Exhaust manifold gasket

Engine ‐ Dismantle and Assemble

Removal and Installation

16‐067Locator for clutch disc

21‐036ARemover for pilot

21‐141Installer for radial oil

21‐147Remover for vibration

4. Remove the crankshaft pulley/vibration damper.

5. Remove the clutch.

6. Loosen the flywheel bolts.

10. Remove the engine lifting eye.

12. Remove the timing chain upper cover.

13. Remove the timing chain lower cover with the

15. Set the camshaft sprockets to the marks.

16. Remove the upper chain guide.

17. Remove the camshaft sprockets.

18. Remove the chain tensioner arm.

20. Remove the timing chain.

23. Remove the cylinder head.

24. Cylinder head bolts, distinguishing features.

26. Remove the oil pump.

27. Remove the components mounted on the left‐

Only on vehicles with air conditioning.

For all vehicles

30. Remove the carbon from the upper edge of the

32. Remove the crankshaft front support bracket.

34. Remove the crankshaft pilot bearing.

35. Remove the pistons.

36. Remove the crankshaft.

Measure bearing clearance

45. Check the piston ring gaps.

50. Install the crankshaft pilot bearing.

Install the rear oil seal carrier.

53. General description of how to fit a radial oil seal

54. Fit the crankshaft rear oil seal.

55. Fit the front support bracket.

Install the sump

59. Put the sump in position using a new gasket.

60. Align the sump.

61. Fit the flywheel.

62. Centre the clutch disc on the clutch pressure plate.

63. Fit the clutch.

64. Dismantle and clean the oil pump.

65. Reassemble the oil pump.

Only on vehicles with air conditioning.

For all vehicles

Install the cylinder head.

73. Fit the cylinder head.

76. Tighten the cylinder head bolts (cont.).

77. Tighten the auxiliary cylinder head bolts.

Oil the bearings.

3. Fit the camshaft bearing caps so that the position

Install timing chain

85. Tighten the chain guide bolts.

86. Install the chain tensioner.

87. Position the camshaft sprockets.

91. Clip a new upper timing chain guide into the

92. Release the chain tensioner hydraulic plunger.