2 4DuraTorq

Technical Service Training
Ford Transit
New Product Introduction TN7002094H
2.4L DuraTorq Turbocharged Diesel Engine
Student Information
CG 7773/S en 10/1999
Introduction Preface
Starting with the 2000 ½ model year the Ford Transit model range is being superseded by completely revised
vehicles. These are new technical developments with some modified components and systems from existing Ford
vehicles.
Since its introduction in 1965, the Ford Transit concept has been continuously developed technically and
economically, making the Transit the leading light commercial vehicle in Europe.
The Transit model range has been enlarged further by one-ton and two-ton variants with three different wheelbases
and body heights, a large number of door combinations and additional technical features such as a navigation
system and parking aid. Now Ford offers the customer a large number of ways in which the Ford Transit can be
tailored even better to his individual requirements.
The engine range for the Ford Transit has been completely revised and for the first time includes a completely new
16 valve turbocharged direct injection diesel engine designed specifically for the Ford Transit delivering a power
output from 75 to 120 PS. The proven 2.3L DOHC 16V petrol engine from the Scorpio/Galaxy will be an
additional engine variant.
The new Ford Transit is being introduced in two stages: the first stage with the two-tonner exclusively with diesel
engines and rear wheel drive, the second stage with the one-tonner and petrol engines for all models. For the first
time a Transit will be available with front wheel drive and a pneumatic rear suspension.
This New Product Introduction publication describes the new one-ton Ford Transit with all the systems and
components while a second New Product Introduction publication will present the one-ton Ford Transit (early in
the year 2000).
This Student Information publication is arranged in lessons and designed as a self-learning medium in line with the
new global Ford training concept.
Each lesson starts with a list of the objectives to be achieved in the course of the lesson and ends with test
questions to check learning progress. The answers to these are to be found at the end of the Student Information
publication.
Please remember that our training literature has been prepared solely for FORD TRAINING PURPOSES.
Repair and adjustment operations MUST always be carried out according to the instructions and
specifications in the workshop literature.
Please make extensive use of the training courses offered by Ford Technical Training Centers to gain
extensive knowledge in both theory and practice.
Service Training 1
Contents Introduction
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Literature/video overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Transit V184/5 for the 2000 3/4 model year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Transit VE 83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lesson 1 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4L DuraTorq turbo diesel engine -- overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
General information on the 2.4L DuraTorq engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Location of engine identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Torque and power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Test questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lesson 2 - Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cylinder head and valve gear -- overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Rocker shafts and rocker arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Camshafts and camshaft carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Camshaft sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Cylinder head and valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Cylinder head gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cylinder head bolt tightening sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Timing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2 Service Training
Introduction Contents
Page
EGR connector and intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Exhaust manifold with turbocharger (wastegate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Water-cooled EGR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Engine charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Test questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Lesson 3 - Cylinder block and crank gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Cylinder block and crank gear -- overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Stiffening frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Stiffening frame bolt tightening sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Test questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Lesson 4 - Engine oil circuit/cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Oil filter/oil cooler unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Cooling system -- overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Coolant supply to oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Water pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Coolant rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Test questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Lesson 5 - Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fuel injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Service Training 3
Contents Introduction
Page
Fuel injection lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Fuel leak-off line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Fuel feed and return line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Fuel lift pump (120 PS variant only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Filter warning indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Bosch VP 30 distributor-type fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Bosch VP 44 distributor-type fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Fitting the fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Test questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Lesson 6 - Engine management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Engine management -- overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Operation of the engine management with the EEC V module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Location of sensors/actuators in the Transit engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

EEC V powertrain control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Data link connector (DLC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Sensor location and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Actuator location and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Pump control unit (PCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Faulty/defective engine management components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Test questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Lesson 7 - Belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
List of abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Answers to the test questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4 Service Training
Introduction Literature/video overview
Transit V184/5

“Ford Transit -- Overview”, CG 7765/S

“Ford Transit -- Body”, CG 7766/S

“Ford Transit -- Front Axle”, CG 7767/S
Technical Service Training
Ford Transit
“Ford Transit -- Brakes”, CG 7769/S
2.4L DuraTorq Turbocharged Diesel Engine
“Ford Transit -- MT-75 Transmission”,
CG 7770/S

“Ford Transit -- Vehicle Electrical Systems and
Air Conditioning”, CG 7772/S
Student Information
CG 7773/S en 10/1999
Video
“Ford Transit”, CG 7826/V
Workshop literature (for example)

-- Repare procedures/TIS
-- Diagnosis and Testing manual
-- Wiring Diagrams
-- Technical Service Bulletins
-- Parts Microfiche/Microcat
-- Technical Data book
Service Training 5
Literature/video overview Introduction
Transit VE 83
Technical Delegate
Information
New Product Introduction
Service Training Transit ’95, CG 7537
CG 7653/S en 9/96
Technician Product Training

Transit ’92, CG 7450
MT-75 5-speed Transmission, CG 7511

New Product Introduction 00/284
Transit
Diesel Injection, Service Checks and
Diesel Injection Systems Adjustments, CG 7506
Diesel Engine Management, CG 7465
EEC V and On-Board Diagnostics,

CG 7543
Diesel Injection Systems, CG 7453
Vehicle System Test Manuals

Wiring Diagrams
New Product Introduction - Transit:

- Body, CG 7643
- Front Axle and Steering, CG 7647
- Rear Axles, CG 7648
Service Microfiche:
- Brakes, CG 7649
- Transit
- Transmission and Clutch, CG 7650
- Automatic Clutch, CG 7736
- Engines, CG 7651
- Vehicle Electrical Systems and
. Air Conditioning, CG 7652
- DOHC Engine Management, CG 7654 Parts Microfiche:
- EPIC Fuel Injection System, CG 7659 - Transit
- A4LD Base Automatic Transmission, - Engine
. CG 7446 - Transmission
6 Service Training
Lesson 1 -- General
Objectives
On completing this lesson, you will be able to:
D locate the main components of the engine
D name the essential new features of the engine
D explain the basic characteristics of the engine
Service Training 7
Lesson 1 -- General
2.4L DuraTorq turbocharged diesel engine -- overview
1 2
11
10
4
7773/01/ESG
1 Intake manifold 6 Oil cooler/oil filter

2 Cylinder head cover 7 Stiffening frame
3 Camshaft carrier 8 oil pan
4 Cylinder head 9 Fully electronic fuel injection pump
5 Water-cooled EGR cooler (not on 10 EGR connector
75 PS variant) 11 EGR valve
8 Service Training
Lesson 1 -- General
2.4L DuraTorq turbocharged diesel engine -- overview (continued)
1 2
7
8
7773/02/ESG
1 Crankcase ventilation system 5 water pump

2 Oil filler cap 6 Timing cover
3 Thermostat housing 7 Vibration damper
4 Power steering pump 8 Exhaust manifold with integral turbocharger
Service Training 9
Lesson 1 -- General
Engine views
Longitudinal view
1
12 2
11 3
10
9 4
7773/03/ESG
1 Fuel injector 7 Piston

2 Rocker arm (intake) 8 Exhaust valve
3 Intake camshaft 9 Exhaust port
4 Intake port 10 Glow plug
5 Intake valve 11 Exhaust camshaft
6 Piston bowl 12 Rocker arm (exhaust)
10 Service Training
Lesson 1 -- General
Engine views (continued)
Cross-section
7773/85/ESG
Service Training 11
Lesson 1 -- General
Brief description
Engine
D New 4-cylinder turbocharged diesel engine with two overhead camshafts and 16 valves.
D Camshaft carrier to support both camshafts.
D Chain-driven camshafts and valves operated by rocker arms with hydraulic tappets to offset changes
in valve clearence.
D Stiffening frame to reduce noise and vibration.
D Chain-driven oil pump mounted under the stiffening frame.
D Oil cooler with integral oil filter.
D Charge air cooled by intercooler system (not on 75 PS variant).
D Bosch (VP 30 or VP 44) fully electronic fuel injection pump.
D Electric fuel lift pump to assist fuel circulation (120 PS variant only).
Engine management
D EEC V engine management (controlling fuel quantity, start of fuel injection and exhaust gas recirculation).
D PCM with 104 pins and integral passive anti-theft system (PATS).
Emission control
D Meets the Stage III exhaust emission standard for 55 kW (75 PS) and 88 kW (120 PS) and the future Stage IV
exhaust emission standard for 66 kW (90 PS).
D Electronically controlled and water-cooled exhaust gas recirculation (EGR).
Diagnostics
D Data link connector (DLC) for FDS 2000/WDS.
D Instrument cluster (engine malfunction indicator lamp).
12 Service Training
Lesson 1 -- General
General information on the 2.4L DuraTorq engine
D Like the Endura-DI engine in the Focus before it, D The camshafts, together with the fuel injection
the 2.4L DuraTorq engine works on the pump, are driven by a twin chain.
direct-injection principle.
D The fuel metering is regulated fully electronically
D The 2.4L DuraTorq engine is the first Ford by a Bosch distributor-type fuel injection pump
turbocharged diesel engine with 16 valves. which comes in two variants according to the
power output (VP 30 up to 90 PS/VP 44 from
D The engine is offered with different levels of power
100 PS).
output:
D The EEC V PCM is used for engine management.
-- with 55 kW/75 PS in the form of a turbocharged
Diagnostics are carried out using FDS 2000 or
diesel engine without intercooling
WDS through the data link connector (DLC).
-- with 66 kW/90 PS in the form of a turbocharged
diesel engine with intercooling D Direct injection diesel engines are generally
economical internal combustion engines. In
-- with 88 kW/120 PS in the form of a addition, with direct injection the emissions of
turbocharged diesel engine with intercooling carbon dioxide (CO2) are lower than with indirect
fuel injection.
D The valves are operated by rocker arms driven by
two overhead camshafts.
Service Training 13
Lesson 1 -- General
General information on the 2.4L DuraTorq engine (continued)
D Increasing demands regarding drivability and noise D This has been largely reduced with this engine by
levels and further drastically reduced exhaust the two-stage fuel injection (resulting in more even
emission limits require new concepts to meet these combustion).
requirements in future.
Fuel consumption Exhaust emission limits
D The low fuel consumption of the engine is the

result of the efficient combustion and high D The Stage III exhaust emission limits are satisfied
injection pressure which has also led to reduced by the use of fully electronic control for the start of
emissions of carbon dioxide (CO2). fuel injection and fuel quantity and by controlling
the boost pressure and exhaust gas recirculation
Noise emissions (not on the 75 PS variant).
D The relatively loud and uneven operation of a

diesel engine with direct fuel injection is caused by D In addition, the engine has ample potential to meet
the “harsh combustion” (hammer). future exhaust emission limits.
14 Service Training
Lesson 1 -- General
Location of engine identification
Engine code and engine serial number
D On the 2.4L engine the engine code (4 digits)

and the engine serial number (2 letters for the 1
year and month and 5 figures for the serial
number) are stamped in the cylinder block on the
exhaust side (level with cylinder No. 4).
D The engine codes are allocated for the engines as

follows: 2
-- 55 kW/75 PS = F4FA
3
7773/04/ESG
-- 66 kW/90 PS = D2FA
1 Engine serial number
-- 88 kW/120 PS = D4FA 2 Vehicle identification number
3 Engine code
D If the engine or cylinder block is changed, the
vehicle identification number must be stamped
in the indicated location.
Engine identification plate
D The engine identification plate is located on the

cover of the timing cover. It contains the
following data:
-- date and time of manufacture
-- engine part number
7773/05/ESG
Engine identification plate
Service Training 15
Lesson 1 -- General
Torque and power output 280 60

[ Nm ] [ kW ]
1
260 50
D The optimum mixture preparation and efficient
240 40
combustion of this engine produce a particularly
well balanced torque curve. 220 30
200 20
D A continuous torque is guaranteed even at low
180 2 10
engine speeds.
160 0
D This also affects the engine power output. 140
120
2.4L DuraTorq engine developing 55 kW 100
80
1000 1500 2000 2500 3000 3500 4000 4500
D The 2.4L DuraTorq engine developing 55 kW 7773/06/ESG [ min - 1 ]
(75 PS) produces its maximum torque of 185
Nm at 2000 min- 1. 55 kW engine
1 Power curve
D The maximum power output is produced at 3500
2 Torque curve
min- 1.
2.4L DuraTorq engine developing 66 kW

300 70
[ Nm ] [ kW ]
D The 2.4L DuraTorq engine developing 66 kW 280 60
1
(90 PS) produces its maximum torque of 200 260 50
Nm at 1800 min- 1.
240 40
D The maximum power output is produced at 4000 220 30

min- 1. 2
200 20
180 10
160 0
140
120
1000 1500 2000 2500 3000 3500 4000 4500
7773/07/ESG [ min - 1 ]
66 kW engine
1 Power curve
2 Torque curve
16 Service Training
Lesson 1 -- General
Torque and power output (continued) 340 90

[ Nm ] [ kW ]
320 80
2.4L DuraTorq engine developing 88 kW
300 70
1
D The 2.4L DuraTorq engine developing 88 kW 280 60
(120 PS) produces its maximum torque of 240 260 2 50
Nm at 2300 min- 1. 240 40
220 30
D The maximum power output is produced at 4000
min- 1. 200 20
180 10
160 0
140
120
7773/08/ESG 1000 1500 2000 2500 3000 3500 4000 4500 [ min --1 ]
88 kW engine
1 Power curve
2 Torque curve
Engine data
Description Measurements
Bore 89.9 mm
Cubic capacity 2402 cc
Stroke 94.6 mm
Compression ratio 19 : 1
Service Training 17
Test questions Lesson 1 -- General
Find the correct answer or fill in the blank spaces.
1. What advantage do direct injection diesel engines offer compared with indirect injection
engines?
V a) Lower fuel consumption and reduced emissions of CO2.

V b) No glow plugs are required.
V c) The engine runs much more smoothly and flexibly.
V d) Minimal overflow losses due to smaller swirl chamber.
2. How are the hammering noises typical of direct injection engines damped in the case of the
2.4L DuraTorq engine?
V a) By the favourable intake swirl.

V b) By the favourable design of the combustion chamber.
V c) By the optimum atomisation of the fuel at the time of injection.
V d) The fuel is injected into the combustion chamber in two stages.
.
3. Which statement is correct?
V a) The direct injection diesel engine has progressive combustion.

V b) The fuel metering is regulated fully electronically by a distributor-type fuel injection pump.
V c) The direct injection diesel engine only requires a small swirl chamber for preparing the mixture.
V d) The low fuel consumption arises from the high fuel injection pressure and not from efficient
combustion.
4. Which engine variant has no intercooler?
V a) 88 kW/120 PS
V b) 66 kW/90 PS
V c) 55 kW/75 PS
V d) 66 kW/90 PS and 88 kW/120 PS
18 Service Training
Lesson 2 -- Cylinder head
Objectives
D name the individual components of the cylinder head
D describe the new components of the cylinder head
D distinguish the intake camshaft from the exhaust camshaft
D explain the advantages of the revised intake geometry
D describe the drive for the camshafts and the fuel injection pump
D explain the advantages of the water-cooled EGR system
D discuss the location of the intercooler (only on vehicles with the 90 and 120 PS engine)
Service Training 19
Cylinder head and valve gear -- overview
1 5
3
7
7773/09/ESG
1 Cylinder head cover 5 Exhaust camshaft

2 Rocker shaft with rocker arms (exhaust) 6 Intake camshaft
3 Rocker shaft with rocker arms (intake) 7 Cylinder head
4 Camshaft carrier 8 Cylinder head gasket
20 Service Training
Cylinder head cover
D The cylinder head cover is made of plastic and D The cylinder head cover is sealed to the camshaft
secured to the camshaft carrier with 12 bolts. carrier with a rubber gasket which is pressed into
the cylinder head cover.
D The cylinder head cover incorporates the crankcase
ventilation valve.
D The cylinder head cover has four bores with

corresponding O-ring seals for the centrally located
fuel injectors.
5
4
3
7773/10/ESG
1 Cylinder head cover 4 O-ring seal

2 Crankcase ventilation valve 5 Fuel injector
3 Rubber gasket
Service Training 21
Rocker shafts and rocker arms
1
4 5 6
2
4
8
7773/11/ESG
1 Rocker shaft for exhaust valves 6 Helical spring

2 Rocker arms for exhaust valves 7 Driving chain connecting links
3 Oil bore 8 Timing marks
4 Rocker shaft for intake valves 9 Rocker shaft identification
5 Rocker arms for intake valves
22 Service Training
Rocker shafts and rocker arms (continued)
D The valves are operated by rocker arms which are D The rocker shafts for the intake and exhaust valves
mounted on two rocker shafts (on the intake and are marked at the front end as follows:
exhaust sides).
-- IN = Intake
D This made it possible to reduce the height of the
engine. -- EX = Exhaust
D The rocker arms are of different lengths to match D When installing a rocker shaft, make sure that the
the offset valves. oil bores face downwards.
D Since the gaps between the intake valves are NOTE: The rocker shafts must be tightened down
greater than the gaps between the exhaust valves, to the specified torque to avoid distortion
helical springs are fitted on the intake rocker shaft of the rocker shafts at the bearing points
between the rocker arms to equalize the spacing. and hence serious damage.
D These helical springs are used to equalize the D In addition, when installing a rocker shaft, make
spacing and keep the rocker arms in the correct sure that the crankshaft is at TDC and that the
position. timing marks on the camshaft sprockets point
vertically upwards to the drive chain connecting
D The rocker arms have hydraulic tappets to offset
links.
changes in valve clearance.
D The oil for these is supplied by the engine oil NOTE: Refer to the current service literature for
circuit through oil bores. the precise adjustment procedure.
Service Training 23
Camshafts and camshaft carrier
1 2
3 4
7773/12/ESG
1 Exhaust camshaft 4 Bearing caps

2 Intake camshaft 5 Bead of sealer
3 Camshaft carrier a Gap between pairs of cams
24 Service Training
Camshafts and camshaft carrier (continued)
Camshafts
D The intake and exhaust camshaft differ in the gap the underside of the cylinder head must be cleaned
“a” between the cams. Since the heads of the intake thoroughly (look at current service literature).
valves are larger, the gap “a” between the pair of
cams is also visibly larger. D Then apply a bead of sealer with a diameter of 2 to
3 mm to the mating face on the underside of the
camshaft carrier with sealing compound (refer to
Camshaft carrier the current service literature).
D The upper mounting of the camshafts is provided

by a camshaft carrier which is fitted with five NOTE: Refer to the current service literature for
bearing caps. the precise procedure for installing the
camshafts and the camshaft carrier.
D The camshaft carrier is bolted flush to the cylinder
head from above.
NOTE: The camshaft carrier and/or the cylinder
D The bearing caps are designed so that they secure
head may not be changed individually,
both camshafts to the cylinder head.
only as a unit.
D The shape of the camshaft carrier prevents incorrect
installation. The tolerances of the components are
precisely matched to one another so the
D Before the camshaft carrier is installed, the mating camshafts could be severely damaged if
faces on the underside of the camshaft carrier and only one part was changed.
Service Training 25
Camshaft carrier bolt tightening sequence
D The camshaft carrier bolts must be tighened in the D To remove the camshaft carrier, the bolts must be
sequence shown in the illustration to avoid damage loosened in the reverse order.
to the camshaft carrier and to the camshafts.
NOTE: Refer to the current service literature for

the tightening torques.
24
22
18 10 4 12 20
14 6 2 8 16
13 5 1 7 15
17 9 3 11 19
21
23
7773/13/ESG 25
26 Service Training
Camshaft sprockets
1
D When the camshaft sprockets are installed, the 3
timing marks on the sprockets must point

vertically upwards and the crankshaft must be 50
degrees before top of dead center (TDC).
2
D In this position each sprocket must be centered

on the camshaft flange using a helical drill bit
3
(6 mm in diameter).
D The camshaft sprockets and the timing chain

must be installed together.
2
7773/14/ESG
NOTE: Refer to the current service literature
for the precise procedure for installing 1 Camshaft sprockets
the camshafts sprockets and adjusting 2 Helical drill bit (6mm in diameter)
the valve timings. 3 Timing mark on camshaft sprocket
Service Training 27
Cylinder head and valves
5
2 3
1
6
7
4 11
8
13
10
12
9
7773/15/ESG
1 Cylinder head 8 Valve stem oil seal

2 Outer cylinder head bolt 9 Exhaust valve
3 Inner cylinder head bolt 10 Intake valve
4 Intake valves 11 Valve stem
5 Valve collets 12 Cylinder head gasket
6 Spring retainer 13 Exhaust valves
7 Spring
28 Service Training
Cylinder head and valves (continued)
D The cylinder head is made of aluminium and vertical fuel injector which guarantees optimum
cannot be reworked. distribution of the fuel in the combustion chamber.
D The relatively tiny amount of heat generated in the

D Two different sizes of necked down bolts are used engine makes sodium filling of the valves
to secure the cylinder head to the cylinder block. unnecessary.
D The inner bolts are the larger of the two. D The valve guides can be changed (refer to the
current service literature).
D Four valves per cylinder ensure improved cylinder D The valve stem oil seal also acts as the lower guide
charging, a compact combustion chamber and a for the valve spring.
Intake ports
1 2
D The 16 valves are arranged offset in the cylinder
head.
D This is due to the shape of the intake ports in the

cylinder head. 3
D Here, one port forms the swirl port which

imparts a swirling movement to the inflowing
7773/63/ESG
charge air, producing improved turbulence in the
combustion chamber and the bowl in the piston 1 Intake port (charging port)
crown. 2 Exhaust ports
3 Intake port (swirl port)
D The other port serves as the charging port which
ensures optimum cylinder charging.
D This intensifies subsequent mixture formation

and creates good conditions for optimum
combustion.
Service Training 29
Cylinder head gasket
1 2
7773/16/ESG
1 Cylinder head gasket

2 Thickness of cylinder head gasket
3 Locating bushings
30 Service Training
Cylinder head gasket (continued)
D The location of the cylinder head gasket is D Two locating bushings are fitted in the cylinder
determined by its design. block to center the cylinder head.
D The use of a four-layer laminated steel cylinder NOTE: If a cylinder head gasket is being
head gasket has increased its service life and changed, only use a new gasket with the
ensured better sealing between the cylinder head same markings.
and cylinder block.
When changing a piston or connecting
D This has led to significant improvements in rod, measure the maximum piston bump
emissions. height and then select the appropriate
gasket.
D The cylinder head gasket is available in three
different thicknesses depending on the piston bump
Damage to the surface of the gasket and
height.
to the mating faces of the cylinder head
and the cylinder block will lead to leaks
D This is marked by stamped holes as follows:
and therefore must be avoided.
-- → = 1.1 ¦ 0.05 mm
Before fitting the new gasket, it is
-- →→ = 1.15 ¦ 0.05 mm important to make sure that there is no
dirt between the layers of the gasket.
-- →→→ = 1.2 ¦ 0.05 mm
This would also lead to leaks.
Service Training 31
Cylinder head bolt tightening sequence
D The cylinder head is secured with two different NOTE: Refer to the current service literature for
types of cylinder head bolt: precise data on the tightening torques.
-- ten M10 x 160 mm bolts

D To remove the cylinder head, loosen the bolts in
-- eight M8 x 120 mm bolts the reverse order.
D The cylinder head bolt tightening sequence is

shown in the illustration. NOTE: When refitting always use new cylinder
head bolts (torque to yield bolts).
D The cylinder head bolts must be tightened in two
stages and then tightened through a further angle
and must not be tightened any more afterwards.
NOTE: The different sizes of bolt are tightened to

different torques.
16 12 14 18
8 4 2 6 10
7 3 1 5 9
15 11 13 17
7773/17/ESG
32 Service Training
Camshaft drive
1 2 3
D The camshaft drive is located in a timing case.
A 4
D The timing case consists of the front part:
-- of the cylinder head, 5
-- of the cylinder block and

9
-- of the stiffening frame.
B
D The camshafts and the fuel injection pump are
driven in the direction of the arrow by a timing 8
chain (twin chain) from a sprocket on the 6
crankshaft spigot.
D When the timing chain is fitted, the marked 7

chain links must line up with the timing marks
C
on the sprockets on the camshafts and the fuel
injection pump. In this position the crankshaft
must be exactly at 50 before TDC. 7773/18/ESG
NOTE: Refer to the current service literature A Cylinder head

for the procedure for adjusting the B Cylinder block
valve timings. Incorrect adjustment can C Stiffening frame
lead to major engine damage. 1 Exhaust camshaft sprocket
2 Chain guide
D A hydraulically operated chain tensioner acts 3 Intake camshaft sprocket
through the chain tensioner arm to ensure 4 Chain guide
permanent and maintenance-free adjustment of 5 Fuel injection pump sprocket
the timing chain. 6 Chain guide
7 Crankshaft spigot sprocket
D The hydraulic system of the chain tensioner is
8 Chain tensioner
supplied with oil from the engine oil circuit.
9 Chain tensioner arm
D The timing chain is guided by three chain guides
and the tensioner arm.
Service Training 33
Timing cover
a
D The complete timing case is sealed with a timing
cover.
D The timing cover is made of steel and fitted 1

using sealing compound (refer to the current ser-
vice literature).
1
2
D Before fitment, the mating faces on the timing
cover and the timing case must be cleaned
thoroughly (refer to the current service
literature).
D When applying the sealing compound, make 7773/41/ESG
sure that the bead of sealer has a diameter of no

a Diameter of bead of sealer
less than 2.5 mm and no more than 3.5 mm.
1 Timing cover
2 Bead of sealer
3 Gasket
D The new Special Tool 21--241 is used to install

the timing cover. This centers the timing cover in 3 1
relation to the crankshaft.

for the precise procedure for installing
the timing cover.
D The coolant outlet connector is attached to the 2
timing case.
D The installation of the coolant outlet connector

and parts of the belt drive to the timing case ma-
kes it necessary to provide additional sealing for
7773/42/ESG
the timing cover.
1 Aluminium gasket
D This is provided by a aluminium gasket.
2 Coolant outlet connector
3 O-ring seal
34 Service Training
EGR connector and intake manifold

1
EGR connector
D The EGR connector is located between the air

intake hose and the intake manifold. 2
D It carries the EGR valve and the IAT sensor

(refer to lesson 6 for a description of this).
3
D Between the EGR connector and the intake
manifold there is a O-ring seal which must be
changed when servicing is carried out.
7773/88/ESG
1 O-ring seal
2 EGR valve
3 IAT sensor
Intake manifold
D The intake manifold is made of plastic.
D It is sealed to the cylinder head with eight sepa-

rate rubber gaskets.
D In service, the gaskets must be checked for

damage and changed if necessary before
installing the intake manifold.
1
for the precise procedure for installing
the intake manifold.
2
7773/19/ESG
1 Intake manifold
2 Rubber gaskets
Service Training 35
Exhaust manifold with turbocharger

(wastegate) 1 2
D The exhaust manifold is made of a steel alloy 3

and forms a unit with the exhaust turbocharger. 4
D If the turbocharger and/or exhaust manifold are

faulty, the complete exhaust manifold and
turbocharger must be changed.
D The exhaust manifold is sealed by means of a

one-piece three-layer laminated steel gasket.
D The plastic sleeve provides the necessary room 5

7773/21/ESG
for expansion when the exhaust manifold gets
hot and must be changed when the exhaust
1 Exhaust manifold gasket
manifold is installed since the sleeve melts.
2 Plastic sleeve
3 Exhaust manifold
4 Turbocharger
5 Oil pipe
36 Service Training
Water-cooled EGR system
D The engines developing 90 and 120 PS are D The enhanced water cooling improves the exhaust
equipped with a water-cooled EGR cooler which is emission values even further in that the formation
connected directly to the engine coolant circuit. of oxides of nitrogen (NOx) and soot particles is
reduced further, the combustion temperature is
D Before the recirculated exhaust gas flows into the lowered and the density of the air/exhaust mixture
intake manifold, it is passed through the EGR is increased.
cooler.
NOTE: A new retaining clip and gasket must be
used.
2 3
4
7773/22/ESG
1 Connection to EGR valve

2 Exhaust manifold
3 Retaining clip
4 Gasket
5 EGR cooler
Service Training 37
Engine charging
Intercooler (90 and 120 PS variants) Connecting pipe (75 PS variant)
D The intercooler required on the 90 and 120 PS D On the 75 PS variant a connecting pipe is installed
variants is mounted on the crossmember under the in place of the intercooler since here the lower
radiator. engine power output is produced without the need
for such a high charge air density.
D The charge air is cooled by the slipstream as the
vehicle moves.
1
2
3
7773/43/ESG
1 EGR valve 5 Hose to intercooler/connecting pipe

2 Crossmember 6 Intercooler (90 and 120 PS variants)
3 Exhaust manifold 7 Connecting pipe (75 PS variant)
4 Turbocharger compressor housing 8 Hose to intake pipe
38 Service Training
Lesson 2 -- Cylinder head Test questions
Find the correct answer or fill in the vacant spaces.
1. The intake and exhaust valves are operated by means of
V a) hydraulic bucket tappets.

V b) rocker arms.
V c) cam followers.
V d) adjustable bucket tappets.
2. The camshafts (on the intake and exhaust side) are distinguished from one another by
V a) the significantly longer exhaust camshaft.

V b) the significantly longer intake camshaft.
V c) the greater gaps between the pairs of cams on the intake camshaft.
V d) marks on the flange of the sprocket on the camshaft concerned.
.
3. Which of the following statements is incorrect?
V a) Four valves per cylinder allow better cylinder charging.

V b) All eight intake ports have the same shape for uniform cylinder charging.
V c) The cylinder head is mounted on the cylinder block with two different types of cylinder head bolts.
V d) The cylinder head is sealed to the cylinder block with a four-layer laminated steel cylinder head
gasket.
4. The camshafts
V a) together with the coolant pump and the fuel injection pump, are driven by a twin chain.
V b) together with the fuel injection pump are not driven by a twin chain.
V c) together with the fuel injection pump are driven by a simplex chain.
V d) are not driven by a toothed belt.
5. Which variants of the 2.4L DuraTorq are equipped with a water-cooled EGR system?
V a) 75 and 90 PS.
V b) 90 and 120 PS.
V c) 120 PS only.
V d) 75 PS only.
Service Training 39
Lesson 3 -- Cylinder block and crank gear
Objectives
D describe the location and function of the stiffening frame
D describe the new features of the connecting rods and pistons
D describe the parts of the crank gear
40 Service Training
Cylinder block and crank gear - overview
1 5
7773/23/ESG
1 Oil pan 5 Bearing cap

2 Stiffening frame 6 Crankshaft
3 Cylinder block 7 Upper bearing shell
4 Lower bearing shell 8 Upper bearing shell No. three with flange
Service Training 41
Oil pan
D The sump is bolted to the stiffening frame from D In addition, the bead of sealer must be applied so
below. that the radius of the bead begins at the start of the
radius on the inside of the oil pan.
D It is made of steel and fitted with sealing D Before the oil pan is installed, the mating faces on
compound (refer to the current service literature). the oil pan and the stiffening frame must be
cleaned.
D When the bead of sealer is applied, it is important NOTE: Refer to the current service literature for
to make sure that the specified diameter of the bead the precise procedure for installing the oil
is maintained (a = 2.5 to 3.5 mm). pan.
7773/24/ESG
1 Bead of sealer 3 Start of radius

2 Inside of oil pan a Diameter of bead of sealer
42 Service Training
Stiffening frame
D A stiffening frame is fitted to the lower part of the D During installation, the stiffening frame must be
cylinder block to stiffen the base structure of the aligned with the clutch housing and the intake side
cylinder block and thus reduce noise. of the engine (arrowed).
D The stiffening frame is made of high-pressure

die-cast aluminium.
D The stiffening frame incorporates an oil baffle plate the precise procedure for installing the
to reduce oil foaming. stiffening frame.
2
1
4
7773/25/ESG
1 Stiffening frame with oil baffle plate 3 Gasket

2 Oil passage 4 Cylinder block
Service Training 43
Stiffening frame bolt tightening sequence
D The stiffening frame is secured to the cylinder D The bolts must be tightened in the specified
block with 22 retaining bolts. sequence as shown in the illustration below.
D Three different lengths of bolt are used:

-- A = M8 x 115 (6 off) the precise tightening torques.
-- B = M8 x 80 (13 off)
-- C = M8 x 35 (3 off)
13 10 5 1 4 9 16
21 A A
B B B B B
B
17 A B 20
18 A
C 15
B B B B
22 A A
B C C 14
B
11 6 2 3
7
8 12 19
7773/83/ESG
44 Service Training
Connecting rods
D The connecting rods are available in three different D An engine may only be fitted with connecting rods
lengths. For identification, the large end and of the same length.
bearing cap are marked with the corresponding
length code (H to J): D The connecting rod bearing shells have no retaining
lugs.
-- H = 149.74 mm D The projection on the connecting rod bearing cap

indicates the position in which it should be
installed (facing the timing case).
-- I = 149.80 mm
D New bearing cap retaining bolts must be used for

-- J = 149.86 mm installation.
9
8
4
7
5
6
7773/26/ESG
1 Circlip 4 Large end 7 Retaining bolts

2 Piston pin 5 Projection 8 Length identification
3 Connecting rod 6 Bearing cap 9 Bearing shell
Service Training 45
Pistons
6
7
A B
2
D 4 E
7773/27/ESG
A Groove for upper compression ring 3 Oil control ring

B Groove for lower compression ring 4 Molybdenum-coated surfaces
C Groove for oil control ring 5 Piston skirt marking
D Piston without oil cooling bores (75/90 PS) 6 Engine cooling code
E Piston with oil cooling bores (120 PS) 7 Skirt diameter code
1 Upper compression ring
2 Lower compression ring
46 Service Training
Pistons (continued)
D The pistons are made of an aluminium alloy and piston crown and the mark on the piston skirt point
fitted with three piston rings: towards the timing chain end of the engine.
-- upper compression ring D The size of piston fitted (skirt diameter code)
matches the bore diameter code for the cylinder
-- lower compression ring
concerned.
-- oil control ring
D 0.5 mm oversize pistons are available for repair
D To ensure optimum sealing of the cylinder, when operations.
installing the piston rings, make sure that the ring
gaps are offset at 120 degrees to one another. D The piston of the 120 PS engine incorporates an oil
gallery for piston cooling. This ensures optimum
D The piston crown incorporates a pronounced bowl
piston cooling given the higher power output and
which is necessary for swirl and direct fuel
hence higher combustion temperature. The oil is
injection in a direct injection diesel engine.
supplied by means of the oil splash nozzles (refer
D The locations on the piston skirt which come into to “Oil splash nozzles” in this lesson).
contact with the cylinder bore incorporate
molybdenum-coated surfaces. These counteract D The engine cooling code indicates whether the
scoring of the cylinder and piston and therefore piston has an oil gallery or not:
increase the life of the engine.
-- 3 = without piston cooling
D When fitting a piston, make sure that the piston is
installed in the correct position. The arrow on the -- 4 = with piston cooling
Service Training 47
Crankshaft
D The crankshaft has induction-hardened journals D The bearing caps are numbered (cylinder Nos. 2, 3
which run in five bearings with clamped two-layer and 4) or marked with the letters “F” (front) or “R”
bearing shells. (rear) and have an arrow which must point towards
the timing case of the engine.
D The bearing shells are made of steel and a
roll-bonded aluminium-tin alloy.
D The crankshaft stroke is 94.6 mm.
D The upper shell of main bearing No. 3 is flanged.
The flange limits the end play of the crankshaft.
3
3
7773/28/ESG
1 Crankshaft 4 Bearing cap

2 Upper bearing shell 5 Lower bearing shell
3 Upper bearing shell No. three with flange
48 Service Training
Cylinder block
D The cylinder block of the 2.4L DuraTorq engine

1 2
is made of gray cast iron.
D The cylinder bores are machined directly in the

block.
D Three different bore diameters are used in

production to ensure very precise adjustment of
the clearance between the pistons and cylinders.
D Once the bore diameter has been established, the

optimum piston is fitted. The pistons are also 3
available in three different sizes in production. 7773/29/ESG
D The mounting for the electronic fuel injection 1 Cylinder block

pump and the timing case are cast in the front 2 Mounting for fuel injection pump
part of the cylinder block. 3 Timing case
Oil splash nozzles

1
D Oil splash nozzles for piston cooling are bolted
in place under the cylinder bores between the
crankshaft bearings.
7773/30/ESG
1 Oil splash nozzle
Service Training 49
Test questions Lesson 3 -- Cylinder block and crank gear
Find the correct answer or fill in the blank spaces.
1. The stiffening frame is made of
V a) high-strength plastic.
V b) heat-treated steel.
V c) aluminium.
V d) gray cast iron like the cylinder block.
2. The projection on the connecting rod large end bearing cap indicates
V a) the length class of the connecting rod.

V b) the installation position.
V c) the grade of the connecting rod.
V d) the engine variant (75, 90, or 120 PS).
3. Which engine variant is fitted with additional piston cooling?
V a) 75 PS.
V b) 90 PS.
V c) 120 PS.
V d) All.
4. What is the purpose of the molybdenum-coated surfaces on the piston skirt?
V a) They reduce wear at the contact points with the cylinder bore and thus increase the life of the
engine.
V b) They provide additional piston cooling.
V c) They ensure that the engine runs more smoothly.
V d) They ensure better lubrication of the piston.
50 Service Training
Lesson 4 -- Engine oil circuit/cooling system
Objectives
D describe the combined oil filter/oil cooler
D describe the oil pump and the oil pump drive
D name the individual parts of the cooling system
D describe the coolant supply to the oil cooler
D explain the function of the coolant rail
Service Training 51
Oil filter/oil cooler
D The engine is lubricated by a forced-feed oil D When fitting the filter element, make sure that the
circulation system with a full-flow oil filter and oil retaining lugs face the filter cover.
cooler.
D The combined oil filter/oil cooler is a new design D The cooling of the oil in the oil cooler is carried
in which the oil filter is incorporated in the oil out using the engine cooling system and is
cooler. regulated by means of a separate thermostat (refer
to “Coolant supply to oil cooler” in this lesson).
D For service this means that instead of the
conventional complete oil filter, here only the filter
element and the O-ring seal need changing. For
this, the residual oil in the oil filter must be drained
first through the oil filter drain plug.
A 4 B
6
3 7
2
8
5
3
7773/32/ESG
A Combined oil filter/oil cooler 4 Oil cooler

B Filter element 5 Oil filter drain plug
1 Oil cooler gasket 6 Filter element
2 Oil pressure switch 7 Retaining lugs
3 Oil filter cover 8 O-ring seal
52 Service Training
Oil pump
Oil pump and oil pump drive
D The oil pump (gear-type oil pump) is bolted to the D The chain tensioner can be compressed easily for
underside of the stiffening frame and is driven installation.
directly from the crankshaft by means of a separate
chain drive.
D The chain is tensioned and guided by means of a the precise procedure for installing the
hydraulic chain tensioner. driving chain and the chain tensioner.
D When the oil pump is installed, the sprocket on the

oil pump must be aligned precisely with the
sprocket on the crankshaft (please see current
service literature).
1 2
7773/33/ESG
1 Oil pump sprocket 3 Crankshaft 5 Driving chain

2 Oil pump 4 Chain tensioner
Service Training 53
Cooling system -- overview
3
6
7773/35/ESG
1 Coolant expansion tank 4 Oil cooler

2 Thermostat 5 Coolant rail
3 EGR cooler 6 Water pump
54 Service Training
Coolant supply to oil cooler
D The oil cooler forms a unit with the oil filter and is D This prevents the flow of coolant through the oil
mounted on the exhaust side of the cylinder block. cooler when the engine is cold so as to ensure that
the engine oil warms up quickly.
D The thermostat opens at a temperature of 75 2C.

D The oil is cooled using the engine cooling system.
This eliminates the additional oil cooler behind the D In service, the coolant hoses must be removed and
vehicle radiator grille. installed with care since the hose connectors on the
oil cooler can deform rapidly or even break off.
When installing the coolant hoses, the marks on the
D The oil cooling is controlled by means of a separate hoses must line up with the marks on the
thermostat which is mounted on the coolant rail. connectors.
1
2
7773/36/ESG
1 Coolant inlet hose 4 Coolant outlet connector

2 Thermostat oil cooler 5 Combined oil cooler/oil filter
3 Coolant inlet connector
Service Training 55
Water pump and thermostat

1
D The water pump is mounted on the front of the
engine (on the intake side). 2
D It is driven by the multigroove V-belt through a

belt pulley.
D The thermostat opens at 88C.
3
7773/37/ESG
1 Thermostat housing
2 Water pump
3 Belt pulley
4 Spacer plate
Coolant rail
1
D The engine is equipped with a coolant rail since
for design reasons the water pump has no direct
feed to the cylinder block (to cool the cylinders).
2
7773/38/ESG
1 Coolant rail
2 Gasket
56 Service Training
Lesson 4 -- Engine oil circuit/cooling system Test questions
1. How does the oil cooling system function?
V a) Using the engine cooling system. It is controlled by a separate thermostat.

V b) By a separate coolant circuit.
V c) Entirely by air cooling produced by the slipstream.
V d) Through a separate connection through the air conditioning.
2. How is the oil pump driven?
V a) By a toothed belt driven from the crankshaft.

V b) By a separate chain drive driven by means of an intermediate shaft from the crankshaft.
V c) By a sprocket which is driven by the timing chain.
V d) By a separate chain drive directly from the crankshaft.
.
3. At what temperature does the thermostat for the oil cooler open?
V a) 85C.
V b) 75C.
V c) 65C.
V d) 55C.
4. At what temperature does the thermostat for the cooling system open?
V a) 94C
V b) 88C
V c) 77C
V d) 70C
Service Training 57
Lesson 5 -- Fuel system
Objectives
D explain how the fuel injectors are aligned
D explain the function and operation of the fuel lift pump on the fuel filter on the 120 PS variant
D bleed the fuel system
D explain the operation of the filter warning indicator on the fuel filter
Fuel injectors
3 4
5
7773/39/ESG
1 Fuel injector 4 Connector for leak-off pipe

2 Steel washers 5 Threaded bore for injector
3 Special Tool 21--237
58 Service Training
Fuel injectors (continued)
D The fuel injectors are screwed vertically into the D A new Special Tool is used to fit the fuel injectors.
cylinder head, positioned centrally between the
valves. D The connectors for the fuel leak-off pipes must be
aligned on the intake side using the Special Tool
D The fuel injectors function on the two-spring 21--237.
nozzle holder principle, like those used on the
intercooled 1.9L TDI diesel engine fitted to the NOTE: Refer to the current service literature for
Galaxy. the precise adjustment specification.
D The steel washers of the fuel injectors must not

D The 6-hole fuel injectors ensure optimum fuel
be changed, turned or mixed up during service
distribution in the combustion chamber.
operations.
D The arrangement of four valves per cylinder allows D The washers must be reused in their original
the use of fuel injectors with a reduced diamter of position.
17 mm and a length according to the engine
variant. D The cylinder head cover must be removed to
remove the fuel injectors.
D The fuel is injected in two stages.
NOTE: The fuel injectors may only be removed
D This makes combustion smoother and thus reduces or installed when the engine is cold and
the hammering noises typical of direct injection must be tightened to the torque specified
diesels. in the service literature.
Service Training 59
Fuel injection lines
D The fuel injection pipes are all of the same

length.
D During installation it is important to make sure

that they are seated free of stress. Deformation of
the fuel injection lines must be avoided.
D If the fuel injection pump and/or the fuel injec-

tors are changed, the fuel injection lines must
also be changed.
7773/44/ESG
Fuel leak-off line

1
D The fuel leak-off line is connected to the
individual injectors by means of hollow screws.
D The surplus fuel from the fuel injectors can flow

away through the fuel leak-off line.
D If the fuel leak-off line is removed, a new fuel 2

leak-off line must be installed.
7773/40/ESG
1 Leak-off line
2 Hollow screws
60 Service Training
Fuel feed and return lines
D Since two different distributor-type fuel injection

pumps are used, different methods are employed
to sccure the fuel return line to the fuel injection
pump, as shown in the illustration.
D If the fuel feed or return line is removed, a new

feed or return line must be installed.
2 1
7773/45/ESG 5 3
1 Fuel feed line

2 Fuel return line
3 Hollow screws (VP 44)
4 Hollow screw (VP 30)
5 Cap nut (VP 30)
6 Hollow threaded pin
Service Training 61
Fuel filter
D The fuel filter is located in the engine

compartment on the bulkhead on the left-hand
side (on LHD vehicles) or on the right-hand side
(on RHD vehicles).
D The fuel preheating is carried out through the

fuel filter.
7773/46/ESG
D For this the fuel filter has a control valve
(bi-metal). Fuel filter in system
-- The control valve opens when the fuel

temperature falls below 15C and thus passes
the fuel to the filter; the warmed fuel flows
back to the fuel injection pump again.
-- The control valve closes at a fuel temperature

of 45C; the fuel is returned to the tank.
D The connectors for the fuel feed line are larger to
avoid confusion between the connectors. 1
2
D To check the filter element, the fuel filter is
6
equipped with a filter warning indicator (refer to
“Filter warning indicator” in this lesson).
D On the 75 and 90 PS variants, a hand pump is 3

incorporated in the upper part of the fuel filter to 4
bleed the system (refer to “Bleeding the fuel

system” in this lesson). 5
7773/47/ESG
1 Hand pump
2 Fuel return line
3 Fuel feed line
4 Bleed valve
5 Fuel filter
6 Fuel filter warning indicator
62 Service Training
D At the base of the fuel filter there is a water

sensor which measures the quantity of water in
the fuel filter. If the quantity of water present 1
exceeds 90 ml, this is indicated by a warning
indicator in the instrument cluster.
2
Removing water from the fuel filter

3
4
D First disconnect the electrical connector from the 7773/48/ESG
water sensor.
1 Fuel filter
D To drain off the water, loosen the drain plug on 2 Water drain plug
the filter three or four turns and drain off 3 Water sensor electrical connector
approximately 100 ml (use a hose and collecting 4 Water in fuel filter warning indicator
container).
Fuel lift pump (120 PS variant only)

1
D Vehicles with a 120 PS engine are equipped with
an electric fuel lift pump.
D This is necessary since the high fuel injection

pump output requires increased fuel circulation
to protect the fuel injection pump against
overheating.
D When the ignition is switched on, the pump is

switched on for a short time to build up pressure;
after the engine starts, the pump runs 2
continuously until the engine is stopped.
7773/49/ESG
1 Fuel lift pump

2 Fuel lift pump electrical connector
Service Training 63
Fuel delivery and pressure regulating valve (120 PS variant)
D The illustration below shows the fuel delivery D This passes the supply of fuel directly to the
through the filter element by the fuel lift pump. low-pressure side of the fuel lift pump until the
system pressure falls below 0.7 bar again and the
pressure regulating valve closes again.
D Between the fuel lift pump and the filter element
there is a pressure regulating valve which opens a
bypass if the fuel pressure exceeds 0.7 bar (10 psi).
A
1
6
5 3
7
4
B
7773/65/ESG
A Pressure regulating valve closed (below 0.7 bar) 4 Filter element

B Pressure regulating valve opened (over 0.7 bar) 5 Fuel outlet
1 Fuel lift pump 6 Pressure regulating valve
2 Bracket 7 Compression spring
3 Fuel inlet
64 Service Training
Bleeding the fuel system

1
75 PS and 90 PS variants
D After various service operations on the fuel

system (changing the filter element, eliminating
leaks), the fuel system must be bled. To do this,
proceed as follows:
4
-- Open the bleed valve 1/4 to 1/2 a turn.
-- Execute 50 to 100 strokes with the hand

pump (using a hose and collecting container).
-- Close the bleed valve and start the engine. 7773/50/ESG
1 Hand pump
2 Bleed valve
120 PS variant
D The fuel system for this engine variant is capable

of bleeding itself through the fuel lift pump after
service operations on the fuel system.
2
D This is controlled by the PCM module if the en-
gine does not fire after a certain time when the
starter motor is operated.
D For this, the fuel lift pump remains activated for

3
a few seconds by a signal from the PCM to bleed
4
the fuel system and/or the fuel filter. 1
NOTE: Operate the starter motor for no more 7773/51/ESG
than 10 seconds and then wait 30

1 CKP sensor
seconds before operating it again so as
2 PCM
to avoid overheating the starter motor.
3 Ignition switch
D Then start the engine. 4 Fuel lift pump
Service Training 65
Filter warning indicator

1
D At certain preset intervals the state of the filter 2
must be checked using the filter warning
3
indicator.
4
5
D For this, the procedure is as follows:
-- 75 and 90 PS variants:
stop the engine.
120 PS variant:
let the engine idle.
-- Open the hood and check the position of the 7773/52/ESG
yellow indicator in the filter warning

Filter warning indicator
indicator (refer to “Reading the indicator” in
1 Yellow indicator
this lesson).
2 Reset button
-- If the indicator is at the extreme end of the 3 Green zone
red zone, the reset button (yellow or black) 4 Clear zone
must be pressed. 5 Red zone
start the engine and let the engine idle for a
few seconds.
-- All variants:
then bring the engine speed to 4000 rpm
within 30 seconds and maintain this for 30
seconds.
stop the engine.
-- All variants:
note the position of the yellow indicator in
the filter warning indicator.
-- If the indicator has returned to the original

position (before the reset button was pressed),
the filter element must be changed.
66 Service Training
Reading the indicator

1
D When the yellow indicator is in the “green” 2
zone:
3
-- the filter element is OK.
4
D When the yellow indicator is in the “clear” zone:
-- the filter element should be changed.
D When the yellow indicator is in the “red” zone:
-- the filter element must be changed.
7773/53/ESG
1 Yellow indicator
2 Green zone
3 Clear zone
4 Red zone
Fuel cooler
1
2
D On vehicles with the 120 PS engine a fuel cooler
is fitted under the vehicle floor behind the fuel
tank.
3
D The cooling is provided by the slipstream. This
prevents the fuel injection pump overheating.
D The fuel cooler is larger or smaller according to

7773/54/ESG
the place of use of the vehicle (depending on the
climate of the territory concerned). Chassis cab variant shown
1 Return to tank
2 Fuel cooler
3 Feed (from the fuel injection pump)
Service Training 67
Bosch VP 30 distributor-type fuel injection pump
4
3
2
5
1
12
11
10 9 8
7773/20/ESG
1 Vane cell pump 6 Axial piston 10 Injection timing advance device

2 Rotation angle sensor 7 High-pressure solenoid valve 11 Cam plate
3 Roller ring 8 Pressure valve 12 Pulse generator
4 Pump control unit (PCU) 9 Fuel injection timing solenoid
5 Plug connection (FITS) valve
68 Service Training
Bosch VP 30 distributor-type fuel injection pump (continued)
D The Bosch VP 30 is controlled electronically and -- the fuel injection timing solenoid (FITS) valve
already used in the Endura-DI turbocharged diesel for the fuel injection point and fuel injection
engine installed in the Ford Focus. On the Ford duration
Transit this pump is used with the 55 kW (75 PS)
and the 66 kW (90 PS) variants. -- the pump control unit (PCU)
D The following requirements are satisfied optimally D In this fuel injection pump a pump pressure of up
through the use of the VP 30: to 900 bar is produced, ensuring a high level of
atomisation energy at the injector and a rapid
-- low pollutant emissions response from the fuel quantity regulating system
through the quick-switching high-pressure solenoid
-- high economy valve.
-- improved drivability D The VP 30 produces an increase of 38% in the fuel

injection pressure at the fuel injector compared
D The VP 30 is an axial-piston distributor-type fuel
with the previous generation VP 37 pump (on the
injection pump which is controlled by a
1.9L TDI engine used in the Galaxy).
high-pressure solenoid valve with fully
electronically regulated fuel quantity and fuel
NOTE: Before the electrical connector of the
injection point.
PCU may be touched, it is imperative to
D The following components are not found on the make sure that no electrostatic discharge
VP 30: takes place. A flashover could damage
the PCU.
-- the control slide which was responsible for the
quantity of fuel injected D The PCU is mounted on top of the fuel injection
pump. It calculates the actuation signals for the
-- the electromagnetic shutoff valve high-pressure solenoid valve and the adjustment of
the start of fuel injection from information from the
-- the needle lift sensor (NLS)
rotation angle sensor and the powertrain control
D The following components are new on the VP 30: module (PCM).
-- the pulse generating rotor and the rotation angle D The fuel system cannot be run dry while the
sensor vehicle is operating. When the residual fuel level
drops to 2%, a signal from the sender unit in the
-- the high-pressure solenoid valve for regulating fuel tank is passed to the EEC V PCM which
the quantity of fuel injected and shutting off the initiates engine bucking and finally switches off the
fuel fuel supply.
Service Training 69
Bosch VP 44 distributor-type fuel injection pump
3 4 5
1 2
6
7
12
9
11 10
7773/57/ESG
1 Vane cell pump 7 Distributor shaft

2 Rotation angle sensor 8 High-pressure solenoid valve
3 Cam ring 9 Pressure valve
4 Pump control unit (PCU) 10 Fuel injection timing solenoid valve
5 PCU electrical connector 11 Fuel injection timing advance device
6 Radial-piston high-pressure pump 12 Pulse generating rotor
70 Service Training
Bosch VP 44 distributor-type fuel injection pump (continued)
D The Bosch VP 44 distributor-type fuel injection D The most important components of the VP 44 are:
pump (radial-piston high-pressure pump) is used
with the 88kW/120 PS engine. -- the vane cell lift pump with the pressure
regulating valve and the overflow throttling
D In this distributor-type fuel injection pump the valve
high-pressure generating principle is based on that
-- the radial-piston high-pressure pump with the
of the Lucas DPC(N) distributor-type fuel injection
distributor shaft and the outlet valve
pump which is already in use in the Escort and
Mondeo. -- the high-pressure solenoid valve
D Like the VP 30 distributor-type fuel injection -- the fuel injection timing advance device with
pump, the VP 44 is also controlled electronically the fuel injection timing solenoid (FITS) valve
by a pump control unit (PCU) and the PCM of the
vehicle. -- the rotation angle sensor
-- the pump control unit (PCU)

D The VP 44 stands out through the following
features: D The combination of these components in a compact
unit makes it possible to match the interaction of
-- high performance and compact construction
the individual function units precisely to one
another.
-- low weight
D In this way, the tight specifications are satisfied and
-- high dynamics in control of fuel quantity and
the required performance features are obtained.
start of fuel injection
D The fuel system cannot be run dry while the
-- high fuel pressures at the fuel injector. vehicle is operating. When the residual fuel level
drops to 2%, a signal from the sender unit in the
D The last point is particularly important for the
fuel tank is passed to the PCM which initiates
exhaust emissions which are becoming increasingly
engine bucking and finally switches off the fuel
significant due to the ever-stricter exhaust
supply.
emissions standards, and not least for reducing fuel
consumption.
Service Training 71
Fitting the fuel injection pump

1
D The distributor-type fuel injection pump is fitted
2
to the timing case with a gasket which is made
of steel with a nitrided surface.
D When the gasket is fitted to the pump, the tabs

on the gasket must be bent over towards the
pump (in the position as shown).
3
7773/61/ESG
1 Steel gasket
2 Distributor-type fuel injection pump
3 Tabs
D The distributor-type fuel injection pump is

secured to the timing case in a predetermined 1
position with three bolts. 4 2
D Subsequent adjustment of the start of fuel

delivery is unnecessary since the start of fuel
delivery is regulated electronically by the PCU
and the PCM.
D When fitting the pump, make sure that the spacer

is fitted on the pump flange.
3
D Bring the adjusting slot to the position shown by
turning the pump flange.
7773/62/ESG
D This is necessary for later fitment of the sprocket
with the driving chain. 1 Distributor-type fuel injection pump
2 Adjusting slot
3 Spacer
4 Pump flange
72 Service Training
Lesson 5 -- Fuel system Test questions
1. Which vehicle variant or variants is/are equipped with an additional fuel lift pump?
V a) 90 PS.
V b) 90 and 120 PS.
V c) 120 PS.
V d) 75 and 90 PS.
.
2. How is the excess quantity of water in the fuel filter indicated?
V a) By the filter warning indicator on the fuel filter.

V b) By a warning indicator in the instrument cluster.
V c) By the water quantity indicator on the fuel filter.
V d) By the signal from the water sensor which prompts the PCM to initiate engine bucking.
3. What is the function of the filter warning indicator on the fuel filter?
V a) It indicates the water level in the filter element.

V b) It serves as a warning when the fuel temperature in the filter element is too high.
V c) It indicates the current flow rate of the fuel through the filter element.
V d) It indicates the state of the filter element.
4. What is the function of the high-pressure solenoid valve on the VP 30 and on the VP 44?
V a) It regulates the quantity of fuel injected and switches off the fuel supply.
V b) It regulates the start of fuel injection.
V c) It produces the necessary high pressure for fuel injection.
V d) It regulates the pressure inside the pump.
5. How does the VP 44 differ mainly from the VP 30?
V a) By the different system for regulating the quantity of fuel injected.

V b) By the manner in which the high pressure is produced.
V c) By the arrangement of the pump control unit (PCU).
V d) By the manner in which the fuel is shut off.
Service Training 73
Notes Lesson 5 -- Fuel system
74 Service Training
Lesson 6 -- Engine management
Objectives
D describe roughly how the engine management works
D name the individual components of the engine management system and show their locations
D explain the function of the individual sensors and actuators in broad outline
General
D Rising fuel prices and growing environmental -- start of fuel injection and quantity of fuel
awareness make the economical direct injection injected matched precisely to every operating
diesel engine increasingly more attractive. condition
D Reducing fuel consumption and simultaneously -- temperature-related starting fuelling

increasing power and torque from the engines are
the prime objectives determining current and future -- tiny tolerances and high precision throughout
development in the area of diesel engineering. the service life of the equipment.
D In addition, modern diesel engines are subject to

D The introduction of fully electronic engine
exacting requirements with regard to pollutant and
management allowed by the use of the Bosch
noise emissions.
VP 30 and VP 34 distributor-type fuel injection
D This leads to increased demands on the fuel pumps means that the 2.4L DuraTorq is able to
injection system and its control. The following are meet the requirements named previously due to the
required: high computing power of the PCM and the pump
control unit (PCU).
-- high fuel injection pressures
-- variable start of fuel injection
-- pre-injection
Service Training 75
13
9
8
10
12
11
7
14
15
16
17
6
18
19
4
5
20
2
21
22
23
1
26
25
24
7773/64/ESG
76 Service Training
Engine management -- overview
Key to engine management overview
1 Manifold absolute pressure (MAP) sensor

2 Intake air temperature (IAT) sensor
3 EGR cooler
4 Intercooler
5 EGR vacuum regulator
6 Exhaust gas recirculation (EGR) position sensor
7 Turbocharger compressor
8 Air cleaner (ACL)
9 Data link connector (DLC)
10 Instrument cluster
11 Accelerator pedal position (APP) sensor
12 Stoplamp switch
13 Ignition switch
14 Turbocharger turbine
15 Oxidation catalyst
16 Turbocharger flap valve
17 Exhaust gas recirculation (EGR) valve
18 Vacuum pump
19 Cylinder head temperature (CHT) sensor
20 Fuel injector
21 Glow plug
22 Crankshaft position (CKP) sensor
23 Fuel tank
24 Fuel filter
25 Electronically controlled Bosch VP 30 or VP 44 distributor-type fuel injection pump
26 Pump control unit (PCU)
Service Training 77
Operation of the engine management with the EEC V PCM
7
1 16
5
14 10
15
11
6
12
13
7773/71/ESG
78 Service Training
D The EEC V PCM engine management affects D From these the PCM calculates the commands for
various processes in the vehicle. the actuators (TTOG the fuel injection pump, EGR
vacuum regulator).
D Physical parameters are measured by the sensors
and converted into electrical signals.
D These electrical signals are sent to the PCM and

processed by it.
Key to the opposite illustration

1 Crankshaft position (CKP) sensor
3 Manifold absolute pressure (MAP) sensor
4 Intake air temperature (IAT) sensor
5 Accelerator pedal position (APP) sensor
6 Stoplamp switch
7 Exhaust gas recirculation (EGR) valve with position sensor
8 EGR vacuum regulator
9 Radiator fan motors
10 Glow plugs
11 Preheat indicator lamp/malfunction indicator lamp (MIL)
12 Wide-open throttle air conditioning cutoff (WAC)
13 Air conditioning compressor clutch (A/C clutch)
14 Ignition switch
15 Bosch VP30/VP44 distributor-type fuel injection pump with pump control unit (PCU)
Service Training 79
Location of sensors/actuators in the engine compartment
1 2 3
4 5
7773/70/ESG
1 Crankshaft position (CKP) sensor 4 Intake air temperature (IAT) sensor

2 Manifold absolute pressure (MAP) sensor 5 EGR vacuum regulator
80 Service Training
EEC V powertrain control module
D The PCM is located behind the facia on the front

left-hand side.
D This performs the engine management, controls

the exhaust system and the operation of the pas-
sive anti-theft system (PATS).
D The PCM controls:
-- the quantity of fuel injected
-- the start of fuel injection

7773/72/ESG
-- the exhaust gas recirculation
-- the preheat system
Data link connector (DLC)

1
D The data link connector (DLC) is located in the
interior by the steering column under the instru-
ment panel.
3
D The system diagnostics for the engine
management system are carried out exclusively
through the DLC.
2
D Comprehensive diagnostic checks can be
performed on all the subsystems and components
through the PCM module.
7773/73/ESG
1 FDS 2000
2 CPU
Service Training 81
Sensor location and function
Crankshaft position (CKP) sensor
D The CKP sensor is located on the cylinder block/

transmission flange.
D The CKP sensor measures the precise angular

position of the crankshaft and the engine speed
inductively. 7773/74/ESG
D The CKP sensor affects the following functions:
-- quantity of fuel injected
-- start of fuel injection
-- EGR system
Cylinder head temperature (CHT) sensor
D The CHT sensor is bolted into the cylinder head

on the transmission side.
D The CHT sensor measures the temperature of the

cylinder head (not the temperature of the
coolant).
D The CHT sensor affects the following functions:

7773/75/ESG
-- idle speed
-- preheat operation
-- EGR system
D In addition, the CHT signal is used for the

coolant temperature display in the instrument
panel and to control the fans.
82 Service Training
Manifold absolute pressure (MAP) sensor
D The MAP sensor is located above the cylinder

head cover.
D The MAP sensor measures the absolute pressure

in the manifold which is a reference value for the
engine load.
D This sensor supplies a signal of between 0 and 5

7773/76/ESG
volts to the EEC V PCM according to the
manifold absolute pressure.
D The MAP sensor affects the following functions:
-- EGR system
Intake air temperature (IAT) sensor
D The IAT sensor is located in the intake pipe in

front of the intake manifold.
D The IAT sensor is a temperature-sensitive

resistor with a negative temperature coefficient
(NTC). As the temperature rises, its resistance
becomes smaller. It is supplied with a voltage
from 0 to 5 V by the EEC V PCM.
D From the signals from the IAT sensor and the

MAP sensor the EEC V PCM calculates the
mass of air charging the engine.
7773/77/ESG
D The IAT sensor affects the following functions:
-- EGR system
Service Training 83
Accelerator pedal position (APP) sensor
D The APP sensor is a resistor whose resistance

varies according to the change of angle of the
accelerator pedal. This is a sliding contact
potentiometer.
D Through the APP sensor the EEC V PCM

receives the signal for the instantaneous
accelerator pedal position. 7773/78/ESG
D The PCM calculates the required quantity of fuel

injected from the signals from the APP sensor
and further parameters.
Stoplamp switch
D The signal from the stop light switch is used to

check the AP sensor (plausibility). This prevents
the maximum engine speed (full throttle) when
the brakes are applied.
1
7773/79/ESG
1 Stoplamp switch
84 Service Training
Actuator location and function
EGR vacuum regulator
D The EGR vacuum regulator is located on the top

of the radiator on the right-hand side.
D The EGR vacuum regulator is a solenoid valve

which converts the signals from the PCM into a
control vacuum for the EGR valve.
D It is supplied from the vacuum pump and

7773/80/ESG
actuated by pulsed signals from the PCM.
D The pulse duty cycle of these signals determines

the vacuum which passes to the EGR valve.
Exhaust gas recirculation (EGR) valve
D The EGR valve is located on the EGR connector.
D Through the EGR valve part of the exhaust gases

are mixed with the fresh air fed to the engine. 1
D This reduces the combustion temperature and the

formation of NOx.
D The vacuum actuation takes place through the

EGR vacuum regulating valve.
D The EGR valve incorporates a sensor which

measures the instantaneous position of the valve 2
7773/81/ESG
and sends a message back to the PCM.
1 EGR valve
2 EGR connector
Service Training 85
Pump control unit (PCU)
D The functions of the distributor-type fuel

injection pump are controlled and monitored by
the electronic pump control unit (PCU). 1
D It has connections to the PCM, to the rotation 2 4

angle sensor, to the high-pressure solenoid valve
3
and to the fuel injection timing solenoid valve.
D The exchange of data takes place with the 5

controller area network (CAN) bus.
D Here, the CAN bus functions as a 6 7 8 9

communications path between the PCM and the
PCU (for a precise description of the CAN bus
refer to the New Product Introduction
“Electrics/Air Conditioning” , CG 7772/S). 10
D The PCU evaluates the signals of the rotation

angle sensor to control the high-pressure
7773/82/ESG
solenoid valve and the fuel injection timing
solenoid valve exactly. 1 Distributor-type fuel injection pump
(mechanical part)
2 Signal of rotation angle sensor
3 Pulsed signal of fuel injection timing solenoid
4 High-pressure solenoid valve actuating signal
5 PCU
6 Quantity of fuel injected
7 Start of fuel delivery
8 Further signals
9 Feedback
10 PCM
86 Service Training
Faulty/defective engine management components
D The following table shows how faulty/defective

components are indicated.
Faulty/defective component EGR is Only idle Reduced Engine is

switched off speed engine power stopped
output
EEC V PCM X
CKP sensor X
CHT sensor X
MAP sensor X
Failure of two potentiometers of APP sen- X

sor
EGR vacuum regulator X
D A fault in the preheat system is indicated by the

preheat indicator flashing.
D If the CHT sensor detects that the engine is

overheating, the power output is first reduced. If
the engine does not cool down after a certain time,
it is switched off.
Service Training 87
Test questions Lesson 6 -- Engine management
1. What is measured with the CHT sensor?
V a) The temperature of the engine coolant.

V b) The temperature of the exhaust valves.
V c) The temperature of the cylinder head.
V d) The engine oil temperature.
2. Which statement is incorrect?
V a) The MAP sensor measures the absolute pressure in the manifold which is a reference for the
engine load.
V b) The air mass charging the engine is not calculated from the signals from the IAT sensor and the
MAP sensor.
V c) The intake air temperature is not required to determine the current engine speed.
V d) The APP sensor supplies the PCM with the signal for the current accelerator pedal position.
.
3. What is the function of the EGR vacuum regulator?
V a) It converts the signals of the PCM into a control vacuum for the EGR valve.
V b) It converts vacuum into an electrical signal for the EGR valve.
V c) It receives a positive pressure and opens or closes the EGR valve as a result.
V d) It tells the PCM the position of the EGR valve.
4. Which sensors/solenoid valves are connected directly to the pump control unit (PCU)?
V a) The rotation angle sensor, the IAT sensor and the high-pressure solenoid valve.
V b) The rotation angle sensor, the high-pressure solenoid valve and the fuel injection timing solenoid
valve.
V c) The CHT sensor, the IAT sensor and the high-pressure solenoid valve.
V d) The CHT sensor, the rotation angle sensor and the high-pressure solenoid valve.
88 Service Training
Lesson 7 -- Belt drive
D All the auxiliary units are driven by means of a D The belt is tensioned by means of a self-adjusting
multigroove V-belt. belt tensioner.
D The illustration shows the variants with and D To remove the belt, the tensioner must be turned
without air conditioning. anti-clockwise by the 3/4 inch opening (arrowed).
3 4
8 2
7 5
9
6
1
3 4
A 2
8
5
B 7
9
6
10
7773/69/ESG
A Basic equipment 5 Coolant pump

B With air conditioning 6 Crankshaft vibration damper
1 Power steering pump 7 Tensioner
2 Fan drive 8 Tensioning pulley
3 Idler pulley 9 Generator
4 Vacuum pump 10 Air conditioning compressor
Service Training 89
List of abbreviations
The abbreviations conform to standard SAE J1930 with the exception of those marked with an asterisk (*).
A/C Air Conditioning DLC Data Link Connector
ACL Air Cleaner EEC V* Electronic Engine Control 5th Generation
APP Accelerator Position Pedal

EGR Exhaust Gas Recirculation
CAN* Controller Area Network

FDS* Ford Diagnostic System
CHT* Cylinder Head Temperature

FITS* Fuel Injection Timing Solenoid
CKP Crankshaft Position

IAT Intake Air Temperature
CO2* Carbon Dioxide

LHD* Left-Hand Drive
CPU* Central Processing Unit

MAP Manifold Absolute Pressure
DI* Direct Injection
90 Service Training
List of abbrivations
MIL Malfunction Indicator Lamp PCM Powertrain Control Module
NLS* Needle Lift Sensor

RHD* Right-Hand Drive
NOx* Oxides of Nitrogen PCU* Pump Control Unit
NTC* Negative Temperature Coefficient

WAC* Wide Open Throttle A/C Cutoff
PATS* Passive Anti-Theft System

WDS* World Wide Diagnostic System
Service Training 91
Answers to the test questions
Lesson 1 -- General Lesson 4 -- Engine oil circuit/cooling system
1. a) 1. a)
2. d) 2. d)
3. b) 3. b)
4. c) 4. b)
Lesson 2 -- Cylinder head Lesson 5 -- Fuel system
1. b) 1. c)
2. c) 2. b)
3. b) 3. d)
4. d) 4. a)
5. b) 5. b)
Lesson 3 -- Cylinder block and crank gear Lesson 6 -- Engine management
1. c) 1. c)
2. b) 2. b)
3. c) 3. a)
4. a) 4. b)
92 Service Training

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What are the major changes to the Ford Transit model range?

What are the major changes to the Ford Transit model range?

What are the new engine options available for the Ford Transit?

What are the new engine options available for the Ford Transit?

Technical Service Training

General information on the 2.4L DuraTorq engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Lesson 2 - Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Camshafts and camshaft carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Lesson 3 - Cylinder block and crank gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Lesson 4 - Engine oil circuit/cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Oil filter/oil cooler unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Cooling system -- overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Water pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Lesson 5 - Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Bosch VP 30 distributor-type fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Fitting the fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Lesson 6 - Engine management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Location of sensors/actuators in the Transit engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Pump control unit (PCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Lesson 7 - Belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Answers to the test questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

New Product Introduction TN7002086H

New Product Introduction TN7002087H

New Product Introduction TN7002088H

New Product Introduction TN7002093H

Workshop literature (for example)

Technician Product Training

MT-75 5-speed Transmission, CG 7511

Diesel Engine Management, CG 7465

EEC V and On-Board Diagnostics,

Diesel Injection Systems, CG 7453

Vehicle System Test Manuals

New Product Introduction - Transit:

On completing this lesson, you will be able to:

D locate the main components of the engine

D name the essential new features of the engine

D explain the basic characteristics of the engine

2.4L DuraTorq turbocharged diesel engine -- overview

1 Intake manifold 6 Oil cooler/oil filter

2.4L DuraTorq turbocharged diesel engine -- overview (continued)

1 Crankcase ventilation system 5 water pump

1 Fuel injector 7 Piston

Engine views (continued)

D Camshaft carrier to support both camshafts.

D Stiffening frame to reduce noise and vibration.

D Chain-driven oil pump mounted under the stiffening frame.

D Oil cooler with integral oil filter.

D Charge air cooled by intercooler system (not on 75 PS variant).

D Bosch (VP 30 or VP 44) fully electronic fuel injection pump.

D Electronically controlled and water-cooled exhaust gas recirculation (EGR).

D Data link connector (DLC) for FDS 2000/WDS.

D Instrument cluster (engine malfunction indicator lamp).

General information on the 2.4L DuraTorq engine

General information on the 2.4L DuraTorq engine (continued)

Fuel consumption Exhaust emission limits

D The low fuel consumption of the engine is the