2.2 Duratorque Timing

Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel – Camshafts Remoal

!"R#$#%& 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 Remoe the ale 'oer. For additional information, refer to: al!e al!e "o!er #$%$&%1' 'ngine & (.%) Durator*&Di+DDi #-uma Diesel+(.%) Durator*&D"i #-uma Diesel+(.() Durator*&D"i #-uma Diesel, /n&!ehicle 0epair + al!e al!e "o!er & ehicles ehicles ith: "ommon 0ail Fuel /njection #$%$&%1' 'ngine & (.%) Durator*&Di+DDi #-uma Diesel+(.%) Durator*&D"i #-uma Diesel+(.() Durator*&D"i #-uma Diesel, /n&!ehicle 0epair. 2 Remoe th the een ngine fr front 'o 'oer. For additional information, refer to: 'ngine Front "o!er #$%$&%1' 'ngin e & (.%) Durator*&Di+DDi #-uma Diesel+(.%) Durator*&D"i #-uma Diesel+(.() Durator*&D"i #-uma Diesel, /n&!ehicle 0epair.  Remoe the o*er steering um +elt. For additional information, refer to: -ower 2teering -ump 3elt & (.%) Durator*&Di+DDi #-uma Diesel+(.%) Durator*&D"i #-uma Diesel+(.() Durator*&D"i #-uma Diesel #$%$&%4 5ccessory Dri!e, 0emo!al and /nstallation. , Dis'onne't the fuel sul lines. For additional information, refer to: 6uick 0elease "oupling #$1%&%% Fuel 2ystem & 7eneral /nformation, 7eneral -rocedures.

 Remo moe th the 'r 'ran nsh sha aft ositi ition (CP) se sensor sor. For additional information, refer to: #$%$&18D 'lectronic 'ngine "ontrols "o ntrols & (.%) Durator*&Di+DDi #-uma Diesel+(.%) Durator*&D"i #-uma Diesel+(.() Durator*&D"i #-uma Diesel "rankshaft -osition #"9- 2ensor #0emo!al and /nstallation, "rankshaft -osition #"9- 2ensor 2 ensor & ehicles ehicles ith: "ommon 0ail Fuel /njection #0emo!al and /nstallation.

1

sing the se'ial tool3 remoe the o*er steering um +elt ulle.



0emo!e the brake !acuum pump retaining bolts.

4 Remoe the ro'er shafts. Discard the retaining bolts.

5

Detension an6 lo' the timing 'hain tensioner. 1 0etract the pawl. 1 -ush the lock in. $. /nsert a pin.

70

Remoe the timing 'hain tensioner an6 the right-han6 timing 'hain gui6e.

77

Remoe the timing 'hain uer gui6e.

72

Remoe the 'amshaft sro'ets an6 the timing 'hain.

7 C"T$8#& 0emo!e the camshaft carrier bolts in the se*uence shown. 0emo!e the camshaft carrier. 7, Remoe the 'amshafts. Discard the camshaft oil seals.

/nstallation 1

"lean the mating faces of the camshaft carrier and the cylinder head with suitable metal surface cleaner.

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C"T$8#&Do not rotate the crankshaft when the special tool is fully located into the flywheel. Failure to follow this instruction will cause damage to crankshaft position #"9- sensor hole.

#8TE&;nly rotate the crankshaft in the n ormal direction of rotation.

#8TE&he special tool must be fully inserted. /nsert the special tool through the "9- sensor hole to achie!e 4% degrees before top dead center #D".

ehicles with common rail fuel injection $ C"T$8#&Do not rotate the crankshaft when the special tool is fully located into the flywheel. Failure to follow this instruction will cause damage to crankshaft position #"9- sensor hole.

#8TE&;nly rotate the crankshaft in the normal direction of rotation.

#8TE&he special tool must be fully inserted. /nsert the special tool through the "9- sensor hole to achie!e 4% degrees before top dead center #D".

5ll !ehicles 8

5pply a (.4 mm diameter bead of  )octite 41% to the mating face of the cylinder head.

4

/nstall the camshafts.

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/nstall the camshaft carrier. ighten the bolts in the se*uence shown in two stages. • 2tage 1: 3olts 1 through (( to ($ =m. • 2tage (: 3olts ($ through (4 to 1% =m. •



/nstall the timing chain tensioner and the right&hand timing chain guide.

>  C"T$8#& he copper links of the timing chain must align with the timing marks on the camshaft sprockets. /nstall the camshaft sprockets and the timing chain.

#8TE&Do not tighten the retaining bolts at this stage. ?  /nsert < mm drill bits through the holes in the camshaft sprockets and install the camshaft sprocket retaining  bolts.

1%

/nstall the timing chain upper guide.

11 )oosen the fuel injection pump sprocket retaining bolts.

1(  C"T$8#& he copper link of the timing chain must align with the timing mark on the fuel injection  pump sprocket. /nsert a < mm drill bit through the hole in the fuel injection pump sprocket and tighten the fuel injection pump sprocket retaining bolts.

1$ #8TE&@ake sure the timing chain tensioner is completely released. Anlock the timing chain tensioner.

18

ighten the camshaft and fuel injection pump sprockets retaining bolts.

14

0emo!e the drill bits.

1<

0emo!e the special tool from the crankshaft position #"9- sensor hole.

1

#8TE&/nstall new rocker shaft retaining bolts.

#8TE&he oil bores of the rocker shafts point downwards. /nstall the rocker shafts. ighten the retaining bolts in two stages. • 2tage 1: 1$ =m. • 2tage (: 84 degrees. •

#8TE&;nly turn the engine in the normal direction of rotation. 1> Asing a suitable screwdri!er, turn the engine clockwise two re!olutions.

1? "heck the camshaft timing by inserting the < mm drill bits through the holes in the camshaft and fuel injection pump sprockets.

ehicles without common rail fuel injection (%

"heck the timing by inserting the special tool in the "9- sensor hole.

ehicles with common rail fuel injection (1

"heck the timing by inserting the special tool in the "9- sensor hole.

((

0emo!e the special tool and the three