Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.

2L Duratorq-TDCi
(Puma) Diesel Camshafts
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 (303-01E Engine - 2.0L Duratorq-Di/TDDi (Puma)
Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair) /
Valve Cover - Vehicles With: Common Rail Fuel Injection (303-01E Engine - 2.0L Duratorq-Di/TDDi (Puma)
Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
2
Remove the engine front cover.
For additional information, refer to: Engine Front Cover (303-01E Engine - 2.0L Duratorq-Di/TDDi (Puma)
Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
3
Remove the power steering pump belt.
For additional information, refer to: Power Steering Pump Belt - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L
Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel (303-05 Accessory Drive, Removal and
Installation).
4
Disconnect the fuel supply lines.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information,
General Procedures).

5
Remove the crankshaft position (CKP) sensor.
For additional information, refer to: (303-14D Electronic Engine Controls - 2.0L Duratorq-Di/TDDi (Puma)
Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel)
Crankshaft Position (CKP) Sensor (Removal and Installation),
Crankshaft Position (CKP) Sensor - Vehicles With: Common Rail Fuel Injection (Removal and Installation).

Using the special tool, remove the power steering pump belt pulley.

Remove the brake vacuum pump retaining bolts.

8
Remove the rocker shafts.
Discard the retaining bolts.

Detension and lock the timing chain tensioner.

1 Retract the pawl.
1 Push the lock in.
3. Insert a pin.

10

Remove the timing chain tensioner and the right-hand timing chain guide.

11

Remove the timing chain upper guide.

12

Remove the camshaft sprockets and the timing chain.

13
CAUTION:Remove the camshaft carrier bolts in the sequence shown.
Remove the camshaft carrier.
14
Remove the camshafts.
Discard the camshaft oil seals.

Installation
1

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

CAUTION: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 (CKP) sensor hole.

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

NOTE:The special tool must be fully inserted.

Insert the special tool through the CKP sensor hole to achieve 50 degrees before top dead center (TDC).

Vehicles with common rail fuel injection

3
CAUTION: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 (CKP) sensor hole.
NOTE:Only rotate the crankshaft in the normal direction of rotation.
NOTE:The special tool must be fully inserted.
Insert the special tool through the CKP sensor hole to achieve 50 degrees before top dead center (TDC).

All vehicles
4

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

Install the camshafts.

Install the camshaft carrier.

Tighten the 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.

Install the timing chain tensioner and the right-hand timing chain guide.

8
CAUTION: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.

9
NOTE:Do not tighten the retaining bolts at this stage.
Insert 6 mm drill bits through the holes in the camshaft sprockets and install the camshaft sprocket retaining
bolts.

10

Install the timing chain upper guide.

11 Loosen the fuel injection pump sprocket retaining bolts.

12
CAUTION:The copper link of the timing chain must align with the timing mark on the fuel injection
pump sprocket.
Insert a 6 mm drill bit through the hole in the fuel injection pump sprocket and tighten the fuel injection pump
sprocket retaining bolts.

13
NOTE:Make sure the timing chain tensioner is completely released.
Unlock the timing chain tensioner.

14

Tighten the camshaft and fuel injection pump sprockets retaining bolts.

15

Remove the drill bits.

16

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

17

NOTE:Install new rocker shaft retaining bolts.

NOTE:The oil bores of the rocker shafts point downwards.
Install the rocker shafts.
Tighten the retaining bolts in two stages.
Stage 1: 13 Nm.
Stage 2: 45 degrees.

18
NOTE:Only turn the engine in the normal direction of rotation.
Using a suitable screwdriver, turn the engine clockwise two revolutions.

19
Check the camshaft timing by inserting the 6 mm drill bits through the holes in the camshaft and fuel
injection pump sprockets.

Vehicles without common rail fuel injection

20

Check the timing by inserting the special tool in the CKP sensor hole.

Vehicles with common rail fuel injection

21

Check the timing by inserting the special tool in the CKP sensor hole.

22

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