Seite 1 von 7

Engine - 2.2L Duratorq-TDCi (63kW/85PS) -

Puma/2.2L Duratorq-TDCi (103kW/140PS)
(PG)/2.2L Duratorq-TDCi (81kW/110PS) -
Puma/2.2L Duratorq-TDCi (85kW/115PS) -
Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma -
Camshafts
In-vehicle Repair
Special Tool(s) / General Equipment
Remover, O-Ring Seal
100-010 (17-063)

Timing Tool, Crankshaft

303-698 (21-251)

Two 6 mm drill bits

Materials
Name Specification
Loctite 510 WSK-M2G348-A7

Removal

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

1. Remove the valve cover.

For additional information, refer to: Valve Cover (303-01B Engine - 2.2L Duratorq-TDCi (63kW/85PS) -
Puma/2.2L Duratorq-TDCi (103kW/140PS) (PG)/2.2L Duratorq-TDCi (81kW/110PS) - Puma/2.2L
Duratorq-TDCi (85kW/115PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma, In-vehicle Repair).

2. Remove the engine front cover.

For additional information, refer to: Engine Front Cover (303-01B Engine - 2.2L Duratorq-TDCi
(63kW/85PS) - Puma/2.2L Duratorq-TDCi (103kW/140PS) (PG)/2.2L Duratorq-TDCi (81kW/110PS) -
Puma/2.2L Duratorq-TDCi (85kW/115PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma, In-vehicle
Repair).

3. Remove the fuel pump.

For additional information, refer to: Fuel Pump (303-04D Fuel Charging and Controls - 2.2L Duratorq-
TDCi (63kW/85PS) - Puma/2.2L Duratorq-TDCi (103kW/140PS) (PG)/2.2L Duratorq-TDCi (81kW/110PS)
- Puma/2.2L Duratorq-TDCi (85kW/115PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma, Removal
and Installation).

4. Disconnect the fuel supply lines.

For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General
Information, General Procedures).

5. Remove the crankshaft position (CKP) sensor.

For additional information, refer to: Crankshaft Position (CKP) Sensor - 2.2L Duratorq-TDCi (Puma)
Diesel (303-14A Electronic Engine Controls, Removal and Installation).

6. Remove the brake vacuum pump.

For additional information, refer to: Brake Vacuum Pump - 2.2L Duratorq-TDCi (63kW/85PS) -
Puma/2.2L Duratorq-TDCi (103kW/140PS) (PG)/2.2L Duratorq-TDCi (81kW/110PS) - Puma/2.2L
Duratorq-TDCi (85kW/115PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma (206-07 Power Brake
Actuation, Removal and Installation).

7. Remove the rocker carrier.

https://app-1alldata-1com-11c4lhm5f14fb.hanbosch.hh-netman.de/alldata/vehicle/info... 04.09.2019
 Seite 2 von 7

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

9. Remove and discard the timing chain tensioner using a 2 mm Punch .

10. Remove the timing chain guides, the camshaft sprockets and the timing chain.

11. NOTICE: Remove the camshaft carrier bolts in the sequence shown.
Remove the camshaft carrier.

https://app-1alldata-1com-11c4lhm5f14fb.hanbosch.hh-netman.de/alldata/vehicle/info... 04.09.2019
 Seite 3 von 7

12. Remove the camshafts.

Installation

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

1. Clean the mating faces of the camshaft carrier and the cylinder head.

2. NOTICE: Do not turn the crankshaft when the special tool is fully located into the
flywheel. Failure to follow this instruction will cause damage to the CKP sensor hole.

NOTE: Only turn the crankshaft in the normal direction of rotation.

NOTE: Make sure that the special tool is fully located in the flywheel so that the engine cannot be rotated
in either direction.
Rotate the crankshaft and insert the special tool through the CKP sensor hole to detect 50 degrees
before top dead center (BTDC).

3. 1.NOTICE:
Clean theMake sure
mating that
faces of the mating faces
the camshaft are
carrier clean
and and free
the cylinder of foreign
head material.
with Plastic Scraper
2. Prime the mating faces with Primer.

https://app-1alldata-1com-11c4lhm5f14fb.hanbosch.hh-netman.de/alldata/vehicle/info... 04.09.2019
 Seite 4 von 7

4. Apply a 2.5 mm diameter bead of Loctite 510 to the mating face of the cylinder head.

5. Install the camshafts.

6. Install the camshaft carrier.

◾ Bolts in the sequence shown in two stages.
◾ Stage 1: Bolts 1 through 22 to 23 Nm.
◾ Stage 2: Bolts 23 through 25 to 10 Nm.

7. NOTICE: The copper links of the timing chain must align with the timing marks on the
camshaft sprockets.
Install the camshaft sprockets and the timing chain using 6 mm drill bits .

https://app-1alldata-1com-11c4lhm5f14fb.hanbosch.hh-netman.de/alldata/vehicle/info... 04.09.2019
 Seite 5 von 7

8. Install the timing chain guides.

9. NOTE: Make sure that a new component is installed.

Install the timing chain tensioner.

10. NOTICE: The copper links of the timing chain must align with the timing marks on the
camshaft sprockets.
Check the camshaft timing by inserting the 6 mm drill bits through the holes in the camshaft sprockets
and correct if necessary.

11. Remove the 6 mm drill bits .

12. Remove the special tool from the crankshaft position (CKP) sensor hole.

13. Install the rocker carrier.

◾ Tighten the retaining bolts in two stages.
◾ Stage 1: 10 Nm.
◾ Stage 2: 30 degrees.

https://app-1alldata-1com-11c4lhm5f14fb.hanbosch.hh-netman.de/alldata/vehicle/info... 04.09.2019
 Seite 6 von 7

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

15. NOTICE: Do not turn the crankshaft when the special tool is fully located into the
flywheel. Failure to follow this instruction will cause damage to the CKP sensor hole.

NOTE: Only turn the crankshaft in the normal direction of rotation.

NOTE: Make sure that the special tool is fully located in the flywheel so that the engine cannot be rotated
in either direction.
Rotate the crankshaft and check the timing by inserting the special tool in the CKP sensor hole.

16. NOTICE: The copper links of the timing chain must align with the timing marks on the
camshaft sprockets.
Check the camshaft timing by inserting the 6 mm drill bits through the holes in the camshaft sprockets
and correct if necessary.

https://app-1alldata-1com-11c4lhm5f14fb.hanbosch.hh-netman.de/alldata/vehicle/info... 04.09.2019
 Seite 7 von 7

17. Remove the special tool and the 6 mm drill bits .

18. Install the brake vacuum pump.

For additional information, refer to: Brake Vacuum Pump - 2.2L Duratorq-TDCi (63kW/85PS) -
Puma/2.2L Duratorq-TDCi (103kW/140PS) (PG)/2.2L Duratorq-TDCi (81kW/110PS) - Puma/2.2L
Duratorq-TDCi (85kW/115PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma (206-07 Power Brake
Actuation, Removal and Installation).

19. Install the CKP sensor.

For additional information, refer to: Crankshaft Position (CKP) Sensor - 2.2L Duratorq-TDCi (Puma)
Diesel (303-14A Electronic Engine Controls, Removal and Installation).

20. Connect the fuel lines.

For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General
Information, General Procedures).

21. Install the fuel pump.

For additional information, refer to: Fuel Pump (303-04D Fuel Charging and Controls - 2.2L Duratorq-
TDCi (63kW/85PS) - Puma/2.2L Duratorq-TDCi (103kW/140PS) (PG)/2.2L Duratorq-TDCi (81kW/110PS)
- Puma/2.2L Duratorq-TDCi (85kW/115PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma, Removal
and Installation).

22. Install the engine front cover.

For additional information, refer to: Engine Front Cover (303-01B Engine - 2.2L Duratorq-TDCi
(63kW/85PS) - Puma/2.2L Duratorq-TDCi (103kW/140PS) (PG)/2.2L Duratorq-TDCi (81kW/110PS) -
Puma/2.2L Duratorq-TDCi (85kW/115PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma, In-vehicle
Repair).

23. Install the valve cover.

For additional information, refer to: Valve Cover (303-01B Engine - 2.2L Duratorq-TDCi (63kW/85PS) -
Puma/2.2L Duratorq-TDCi (103kW/140PS) (PG)/2.2L Duratorq-TDCi (81kW/110PS) - Puma/2.2L
Duratorq-TDCi (85kW/115PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma, In-vehicle Repair).

https://app-1alldata-1com-11c4lhm5f14fb.hanbosch.hh-netman.de/alldata/vehicle/info... 04.09.2019