FORD Transit 2.

4 TDCi 140 Duratorq H9FB

Timing chain: removal/installation

General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Removal
Release the fuel pressure
Disconnect the battery earth cable
Disconnect the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Remove the injectors
Disconnect the temperature sensor (cylinder head)
(2.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Remove the drive belt cover

(12.00)

Removal
Remove the oil filler tube
(3.00)
Release the fuel pressure
Disconnect the battery earth cable
Disconnect the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Remove the injectors
Disconnect the temperature sensor (cylinder head)
(2.00)
Timing chain: removal/installation
Remove
Generalthe inlet manifold
(11.00)
Before disconnecting the battery cable, check the audio system security code
(1.00)

Disconnect the positive crankcase breather hoses from the valve cover
(20.00)

Removal
Release the fuel pressure
Disconnect the battery earth cable
Disconnect the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Remove the
Remove the injectors
valve cover
(21.00)
Disconnect the temperature sensor (cylinder head)
(2.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Remove the engine lower cover

Turn the tensioner clockwise to release the belt tension
(22.00)

Removal
Release the fuel pressure
Disconnect the battery earth cable
Remove the ancillary drive belt
Disconnect the injector wiring
Drain the cooling system
Disconnect the fuel lines
Remove the bumper front panel
Disconnect the fuel return line
Remove the front bumper
Remove the fuel injector clamps
Remove the radiator cross member
Remove the injectors
Remove the upper radiator hose
Disconnect the temperature sensor (cylinder head)
Remove
(2.00) the radiator fan and shroud
Disconnect the starter motor wiring
Remove the starter motor
Fit the flywheel locking tool (303-393)
Timing chain: removal/installation
Remove
Generalthe vacuum pump
Note: Do
Before disconnecting
not disconnect
the the
battery
circuit
cable, check the audio system security code
(1.00)
Remove the coolant pump but do not disconnect
(23.00)

Disconnect the water hose from the thermostat

Remove the thermostat housing
(4.00)
Removal
Release the fuel pressure
Disconnect the battery earth cable
Disconnect the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Remove thethe
Disconnect injectors
coolant outlet and degas connector from the engine
(25.00)
Disconnect the temperature sensor (cylinder head)
(2.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Disconnect the crankshaft position sensor

Remove the crankshaft position sensor
Remove the drive belt idler pulley
Remove the fan pulley
(28.00)

Removal
Release the fuel pressure
Disconnect the battery earth cable
Remove the crankshaft pulley
Disconnect the injector wiring
Use the special tools to remove the crankshaft pulley (303-1310)
Disconnect
(29.00) the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Remove the injectors
Disconnect the temperature sensor (cylinder head)
(2.00)

Remove the oil seal

Timing chain: removal/installation
Use the special tool
General (303-679)
(30.00)
Before disconnecting the battery cable, check the audio system security code
(1.00)

Remove the timing cover upper bolts

Remove the timing cover lower bolts
(31.00)

Removal
Release the fuel pressure
Remove the timing cover
Disconnect the battery earth cable
Use a wide flat spatula (303-428)
Disconnect
(32.00) the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Remove the injectors
Disconnect the temperature sensor (cylinder head)
(2.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Compress the tensioner

Lock the tensioner; use a locking pin
(33.00)

Removal
Release the fuel pressure
Disconnect the battery earth cable
Disconnect the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Remove the chain
injectors
tensioner
Remove thethe
Disconnect chain
temperature
guide(s) sensor (cylinder head)
(2.00)
(34.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Remove the injection pump gearwheel

(35.00)

Removal
Release the fuel pressure
Disconnect the battery earth cable
Disconnect the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Remove the injectors
Disconnect the temperature sensor (cylinder head)
(2.00)
Remove the camshaft gearwheel(s) together with the timing chain
(36.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Remove the drain plug

Drain the engine oil
Renew the drain plug (23 Nm)
(37.00)

Removal
Release the fuel pressure
Disconnect the battery earth cable
Disconnect the injector wiring
Disconnect the fuel lines
Remove the lower oil sump
Disconnect the fuel return line
Use a wide flat spatula
Remove the fuel injector clamps
(38.00)
Remove the injectors
Disconnect the temperature sensor (cylinder head)
(2.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Lock the tensioner; use a locking pin

Remove the oil pump chain tensioner
(40.00)

Removal
Release the fuel pressure
Disconnect the battery earth cable
Disconnect the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Remove the injectors
Disconnect the temperature sensor (cylinder head)
(2.00)
Remove the oil pump tube
(41.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Fit the special tool (303-705)

(42.00)

Removal
Release the fuel pressure
Disconnect the battery earth cable
Remove thethe
Disconnect oil pump
injector wiring
(44.00)
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Remove the injectors
Disconnect the temperature sensor (cylinder head)
(2.00)
Timing chain: removal/installation
Remove
Generalthe oil pump chain
(39.00)
Before disconnecting the battery cable, check the audio system security code
(1.00)

Installation
Refit the oil pump chain
Refit the oil pump
Note: Do not tighten the bolts
(43.00)

Removal
Release the fuel pressure
Disconnect the battery earth cable
Disconnect the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Align
Removethethe
oil fuel
pump injector clamps
Use the special
Remove tool
the injectors (303-705)
(42.00)
Disconnect the temperature sensor (cylinder head)
(2.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Tighten the bolts (10 Nm)

(44.00)

Removal
Refit thethe
Release oil fuel
pump chain tensioner
pressure
(40.00)
Disconnect the battery earth cable
Disconnect the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Remove the injectors
Disconnect the temperature sensor (cylinder head)
(2.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Unlock the tensioner

Refit the oil pump tube (10 Nm)
(41.00)

Removal
Release the fuel pressure
Disconnect the battery earth cable
Disconnect the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Remove the injectors
Disconnect
Apply theastemperature
sealant indicated sensor
(Ø3 mm)(cylinder head)
(2.00)
(7.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Refit the lower oil sump

Note: The cover must be fitted within (X) minutes of applying the sealant (X = 5)
(38.00)

Removal
Release the fuel pressure
Disconnect the battery earth cable
Disconnect the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Remove the injectors
Tighten the bolts
Disconnect the temperature sensor (cylinder head)
In the order shown
(2.00)
Stage 1: (7 Nm)
Stage 2: (14 Nm)
(24.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Turn the crankshaft to 50° BTDC

Fit the crankshaft locking tool (303-698)
(26.00)
Removal
Release the fuel pressure
Disconnect the battery earth cable
Disconnect the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Remove the injectors
Refit the camshaft gearwheels
Disconnect the temperature sensor (cylinder head)
Align
(2.00)the coloured chain link with the marks on the gearwheels
Fit the timing chain
(19.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Lock the camshaft gearwheels

Use locking pins (Ø6 mm)
Tighten the camshaft gearwheel bolts lightly until there is no play
(18.00)

Removal
Release the fuel pressure
Position thethe
Disconnect timing chain
battery on the
earth injection pump gearwheel
cable
Align the injection
Disconnect pumpwiring
the injector timing marks
Fit the gearwheel
Disconnect the fueltogether
lines with the chain
Lock the injection
Disconnect the fuelpump
returngearwheel
line
Fit the injection
Remove the fuel pump gearwheel
injector clamps locking tool (Ø6 mm)
Tighten
Remove the
the injection
injectors pump gearwheel bolts lightly until there is no play
(17.00)
Disconnect the temperature sensor (cylinder head)
(2.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Note: Temporarily remove the oil pump chain tensioner bolt

Refit the chain guide(s) (15 Nm)
Fit the chain tensioner
Renew the bolt(s) (15 Nm)
(16.00)

Removal
Release the fuel pressure
Disconnect the battery earth cable
Disconnect the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Remove the injectors
Disconnect the temperature sensor (cylinder head)
(2.00)

Unlock the tensioner

(15.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Tighten the camshaft gearwheels (33 Nm)

Tighten the injection pump gearwheel (33 Nm)
(14.00)

Removal
Release the fuel pressure
Disconnect the battery earth cable
Disconnect the injector wiring
Disconnect the fuel lines
Remove all the
Disconnect the fuel
locking
return
pinsline
(13.00)
Remove the fuel injector clamps
Remove the injectors
Disconnect the temperature sensor (cylinder head)
(2.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Remove the crankshaft locking tool (303-698)

(26.00)

Removal
Release the fuel pressure
Turn the crankshaft clockwise 2 rotations
Disconnect the battery earth cable
(10.00)
Disconnect the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Remove the injectors
Disconnect the temperature sensor (cylinder head)
(2.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Check the timing marks

Fit the locking pins to check the timing (Ø6 mm)
(13.00)

Removal
Release the fuel pressure
Disconnect the battery earth cable
Disconnect the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Fit the crankshaft
Remove lockingclamps
the fuel injector tool (303-698)
(26.00)
Remove the injectors
Disconnect the temperature sensor (cylinder head)
(2.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Remove all the locking pins

(13.00)

Removal
Release the fuel pressure
Remove the crankshaft locking tool (303-698)
Disconnect the battery earth cable
(26.00)
Disconnect the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Remove the injectors
Disconnect the temperature sensor (cylinder head)
(2.00)

Check the chain tension

Refit the crankshaft position sensor (7 Nm)
(27.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Renew the gasket

(9.00)

Removal
Release the fuel pressure
Disconnect the battery earth cable
Disconnect the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Remove the injectors
Apply sealant
Disconnect theastemperature
indicated sensor
(Ø3 mm)(cylinder head)
(2.00)
(8.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Refit the timing cover

Note: The cover must be fitted within (X) minutes of applying the sealant (X = 5)
Use the special tool (303-682)
(6.00)

Removal
Release the fuel pressure
Disconnect the battery earth cable
Disconnect the injector wiring
Tighten thethe
Disconnect nutsfuel lines (10 Nm)
Tighten the the
Disconnect bolts (14 Nm)
fuel return line
(5.00)
Remove the fuel injector clamps
Remove the injectors
Disconnect the temperature sensor (cylinder head)
(2.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Renew the oil seal(s)

Use the special tool (303-679)
(30.00)
Removal
Release the fuel pressure
Disconnect the battery earth cable
Disconnect the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Refit the idler pulley (53 Nm)
Remove the injectors
Fit the cooling fan pulley (53 Nm)
Disconnect
(28.00) the temperature sensor (cylinder head)
(2.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Refit the thermostat housing (23 Nm)

Reconnect the thermostat hoses
(4.00)

Removal
Release the fuel pressure
Connect the coolant outlet and degas connector to the engine (23 Nm)
Disconnect the battery earth cable
Renew the O-ring
Disconnect the injector wiring
(25.00)
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Remove the injectors
Disconnect the temperature sensor (cylinder head)
(2.00)

Fit the coolant pump (22 Nm)

Renew the gasket
Timing chain: removal/installation
Fit the vacuum pump
General (22 Nm)
(23.00)
Before disconnecting the battery cable, check the audio system security code
(1.00)

Refit the crankshaft pulley

Use the special tools to refit the crankshaft pulley (303-1310)
Tighten the crankshaft pulley outer bolts
Stage 1: (45 Nm)
Stage 2: (90°)
Removal
(29.00)
Release the fuel pressure
Disconnect the battery earth cable
Disconnect the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Remove the injectors
flywheel locking tool (303-393)
Refit the starter
Disconnect motor
the temperature (35 Nm)(cylinder head)
sensor
(2.00)
Reconnect the starter motor wiring
Refit the radiator fan and shroud
Refit the radiator upper hose
Refit the cross member (25 Nm)
Timing chain: removal/installation
Refill
Generalthe cooling system
Refit the
Before disconnecting
front bumperthe battery cable, check the audio system security code
(1.00)
Refit the ancillary drive belt
(22.00)

Refit the valve cover

Renew the gasket
Tighten the bolts (10 Nm)
Removal
(21.00)
Release the fuel pressure
Disconnect the battery earth cable
Disconnect the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Remove thethe
Reconnect injectors
positive crankcase breather hoses to the valve cover
(20.00)
Disconnect the temperature sensor (cylinder head)
(2.00)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
(1.00)

Refit the inlet manifold (15 Nm)

Renew the gasket
(11.00)

Removal
Release the fuel pressure
Disconnect the battery earth cable
Disconnect the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Fit the belt cover
Remove the injectors
(12.00)
Disconnect the temperature sensor (cylinder head)
(2.00)
Timing chain: removal/installation
Connect
Generalthe temperature sensor
(2.00)
Before disconnecting the battery cable, check the audio system security code
(1.00)

Refit the oil filler tube

(3.00)

Removal
Release the fuel pressure
Disconnect the battery earth cable
Disconnect the injector wiring
Disconnect the fuel lines
Disconnect the fuel return line
Remove the fuel injector clamps
Remove the injectors
Renew the seals
Disconnect the temperature sensor (cylinder head)
(2.00)
Refit the injectors
Refit the fuel injector clamps
Renew the bolt(s) (6 Nm + 180°)
Renew the injection lines (5 Nm + 35 Nm)
Timing chain: removal/installation
Reconnect
General the fuel return line
Reconnect
Before disconnecting
the fuel injector
the battery
wiringcable, check the audio system security code
(1.00)
Refill the engine oil
Reconnect the battery earth cable

Torque settings
Valve cover: (10 Nm)
Timing chain cover:
Bolt(s): (14 Nm)
Nut(s): (10 Nm)
Oil sump (7 Nm + 14 Nm)
Oil drain plug: (23 Nm)
Chain tensioner (15 Nm)
Chain guide: (15 Nm)
Idler pulley: (53 Nm)
Thermostat housing (23 Nm)
Inlet manifold:
Removal (15 Nm)
Crankshaft
Release thepulley:
fuel pressure (45 Nm + 90°)
Camshaft
Disconnectgearwheels:
the battery earth (33 Nm)
cable
Injection
Disconnectpump gearwheel:
the injector (33 Nm)
wiring
Fuel lines: crown
Disconnect the fuelnuts
lines (5 Nm + 35 Nm)
Clamp
Disconnect the(6fuel
Nmreturn
+ 180°)
line
Crankshaft
Remove theposition sensor:
fuel injector (7 Nm)
clamps
Coolant
Remove pump:
the injectors (22 Nm)
Cross member:
Disconnect (25 Nm)(cylinder head)
the temperature sensor
(2.00)
Special tools
Crankshaft pulley removal tool: (303-1310)
Crankshaft locking tool: (303-698)
Flywheel locking tool: (303-393)
Timing chain: removal/installation
Oil seal fitting tool:
General (303-679)
Oil pump
Before disconnecting
aligning tool:
the battery
(303-705)
cable, check the audio system security code
(1.00)
Fuel injector alignment tool: (303-711)

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