Engine Mechanical - 2.0L: Overhaul Ford Transit VII

Disassembly

Note. If the components are to be reinstalled, mark the location of the components removed, they must be installed in the same location.

Scheme 56

1. Remove the bolts and the 2 lifting eyes. NOTE: One lifting eye shown in illustration, other lifting eye similar.
2. Remove the 4 bolts and the coolant outlet. Discard the gasket.
3. Remove the 2 bolts and the EGR valve. Discard the gasket.
4. Remove the Cylinder Head Temperature (CHT) sensor.
5. Remove the EGR tube.
6. Remove the spark plugs.
7. Using the Valve Spring Compressors, compress the valve spring and remove the valve spring collets, the valve spring retainers and the valve springs. NOTE: Use a small screwdriver and multi-purpose grease to remove the valve collets.
8. Inspect the valve spring, valve spring retainer and valve spring retainer key. For additional information, to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-356743) .
9. Remove the valves.
10. Using the Valve Stem Oil Seal Remover and Slide Hammer, remove and discard the valve seals.
11. Inspect the valves. For additional information, to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-356743) . Install new parts, as necessary.

Scheme 57

1. Install the valves. NOTE: If installing the original valves, make sure the valves are installed in the same position from which they were removed. Coat the valve stems with clean engine oil.
2. Lubricate the valve stems and guides with clean engine oil and, using the Valve Stem Oil Seal Installer, install the valve seals onto the cylinder head valve guides. NOTE: Use the protector provided with the replacement kit to prevent damage to the valve seals.
3. Place the valve spring in position over the valve and install the valve spring retainer.
4. Using the Valve Spring Compressors, compress the valve spring and install the valve collets. NOTE: Use a small screwdriver and multi-purpose grease to install the valve collets.
5. Install the spark plugs. NOTE: Only use hand tools when removing or installing the spark plugs, or damage can occur to the cylinder head or spark plug. Tighten to 12 N.m (106 lb-in).
6. Install the EGR tube. Tighten to 55 N.m (41 lb-ft).
7. Install the CHT sensor. Tighten to 12 N.m (106 lb-in).
8. Using a new gasket, install the EGR valve, and the 2 bolts. Tighten to 20 N.m (177 lb-in).
9. Using a new gasket, install the coolant outlet and the 4 bolts. Tighten to 10 N.m (89 lb-in).
10. Install the 2 lifting eyes and the bolts. NOTE: One lifting eye shown in illustration, other lifting eye similar. Tighten to 45 N.m (33 lb-ft).

1. Remove the piston rings from the piston. Discard the piston rings.
2. Remove the 2 piston pin retainers and the piston pin.
3. Separate the piston from the connecting rod. NOTE: If the piston and connecting rod are to be reinstalled, they must be assembled in the same orientation. Mark the piston orientation to the connecting rod for reassembly.
4. Clean and inspect the piston and connecting rod. For additional information, to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-356743) .

Assembly

1. Align the piston-to-connecting rod orientation marks, and position the connecting rod in the piston. NOTE: The arrow on the top of the piston points towards the front of the engine.
2. Lubricate the piston pin and pin bore with clean engine oil.
3. Install the piston pin in the piston and connecting rod assembly.
4. Install the piston pin retaining clips in the piston.
5. Lubricate the piston and the new piston rings with clean engine oil.
6. Install the piston rings onto the piston as shown in illustration. Piston pin Upper oil control ring gap location Lower oil control ring gap location Center line of the piston pin bore and the expander gap