No.

TT8371

Ford Diesel Engine Setting/Locking & Injection Pump Removal/Installation Set

It is essential to ensure that the front crankshaft seal is correctly installed and aligned. Also, comes with the tools
for the removal/installation of H.P pump. Applicable for Ford Duratorq (Puma) 2.0, 2.2, 2.4, & 3.2 Litre Diesel
Engines in Citroen, Fiat, Ford, Jaguar, Land Rover, LDV, Peugeot.
Application:
Ford Duratorq (Puma) 2.0, 2.2, 2.4 & 3.2L Diesel Engines in:
Model:
Citroen: Relay (06-11), Jumper III
Fiat: Ducato (06-11)
Ford: Mondeo (00-07), Transit (00-11)
Jaguar: X-Type (01-10)
Land Rover: Defender (07-11)
LDV: Convoy (02-06)
Peugeot: Boxer III (06-11)

Engine Code:
2.0: ABFA, D3FA, D5BA, D6BA, F3FA, FIFA, FMBA, HJBA, HJBB, HJBC,
HJBE, N7BA, N7BB
2.2 (Chain Driven H.P.Pump): QJBA (BG), QJBB, QJBC, QJBD
2.2 (Camshaft Driven H.P. Pump): 4HM, 4HU, 4HV, P8FA, P22DTE, QVFA, QWFA
2.4: 244DT, D0FA, D2FA, D2FB, D4FA, F4FA, FXFA, H9FA, H9FB, HEFA,
HFFA, JXFA, PHFA, ZSD 424
3.2: SAFA (Engine Timing Only)
Fuel Injection Pump Sprocket Locking Tool
2.2L Duratorq TDCi (Global Puma)
Stage V Diesel: (303) Engine: (3) Power Train: 2006.5 (04/2006- ) : Transit

3.2L Duratorq TDCI (Puma) Diesel: (303) Engine: (3) Power Train: 2006.5 (04/2006-): Transit
2.2L Duratorq TDCi (Puma) Diesel: (303) Engine: (3) Power Train: 2012.00 (04/2011-): Ranger
3.2L Duratorq TDCI (Puma) Diesel: (303) Engine: (3) Power Train: 2012.00 (04/2011-): Ranger

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Contents:

Ref OEM Description

A 303-682 Engine Cover Aligner
B 303-679A Engine Cover / Crankshaft Seal Removal / Installation Tool
C 303-1151 High Pressure Pump Sprocket Retaining Tool
D 303-249 H.P. Pump Removal Tool
E 303-675 Flywheel Locking Pin (Black)
F 303-698 Flywheel Locking Pin (Silver)
G 6mm Drill Bit Locking Pin Set (3 x Pins)
H 2mm Pin Tensioner Locking Pin
I 303-1317 Fuel Injection Pump Sprocket Locking Tool

Instruction: Removal of the timing cover requires

Section 1 Engine Timing(Setting & Locking disassembly/removal of a number of components
engine) including EVR valves, air intake ducting, radiator,
When carrying out service work on the timing chains, viscous fan and auxiliary drive belt.
cylinder head, chain tensioner, etc., the crankshaft, Note:When removing the timing chain cover, great
camshaft and injection pump timing positions are care must be taken not to distort the cover. If the
retained with locking pins. The 3 pins of cover is damaged or distorted during removal, then a
(G) set are required for the camshafts (x2) and new cover should be used.
injection pump (x1). 1. Flywheel Locking Pins (Gold/Silver)
A larger locking pin is required for the flywheel 1-1 To insert (E) or (F) in the correct datum hole,
(crankshaft). There are two types of locking pin, first remove the crankshaft position sensor and then
Silverfor common rail engines, and Gold for position the flywheel by turning the crankshaft
non-common rail engines. clockwise until the timing hole in the injection pump
The timing chain cover must be removed to gain sprocket is positioned at a point just before it is fully
access to the camshaft sprockets, injection pump, aligned.
timing chains etc.

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Fig.1 WARNING: DO NOT use the Flywheel Locking Pin

to counter-hold the crankshaft when releasing or
tightening the crankshaft pulley bolts. The flywheel
pin is located through the sensor holder which will be
damaged if used to restrain the crankshaft. DO NOT
turn the engine with the flywheel pin fitted.
2. (G) comprises 3 locking pins, 1 for each of the
camshafts and 1 for injection pump timing.
Fit the 3 pins in position and release the camshaft
sprocket bolts and the 4 injection pump sprocket bolts.
Fig.3

Use the injection pump timing hole to help find the

flywheel positionfor inserting thelockingpin
1-2 Insert the flywheel pin through the sensor holder
so it rests on the flywheel ring. Apply slight pressure
to the end of the pin and turn the crankshaft slowly
and carefully until the pin engages the slot in the 3. Tensioner Locking Pin
flywheel ring. 3-1 To remove the timing chain, the chain tensioner
The crankshaftis now at 50° BTDC must be „locked back‟ and removed.
Fig.2 Release (1) and simultaneously push back (2) and
insert (H) through the hole (3) to lock back tensioner.
Fig.4

Engine shown with gearbox removed

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3-2 Remove the tensioner, rail and chain guides. Mark Ensure that the engine and front cover mating
the camshaft sprockets as “inlet” and “exhaust” before surfaces are clean and that any old sealant has been
removing them, along with the injection pump removed.
sprocket and timing chain. 5-1 Locate (B) onto the three holes of the crankshaft
IMPORTANT: (G) are designed to allow removal of front oil seal. Then locate (A) onto (B) and remove
the sprockets without removing the timing pins. the seal by rotating in an anti-clockwise direction.
DO NOT remove the pins from their timing holes Fig.5
when sprockets have been removed.
3-3 When re-assembling the sprockets, chain and
front end, ensure that the 3 copper colored links on the
timing chain align with the timing marks on all three
sprockets, and the chain is taut on the non-tensioned
side. Loosely fit the camshaft and injection pump
sprocket bolts (finger tight only).
Re-fit the chain guides and tensioner, then withdraw
(H) from the tensioner to activate it.
Tighten all sprocket bolts to the specified torque and
then remove the locking pins.
4. Timing Check
To ensure engine timing is correct, turn the engine
over, by hand, two revolutions, returning to 50° BTDC
and insert the correct flywheel locking pin.
Check that the 3 x (G) can be inserted into the timing 5-2 Apply a 3mm bead of a suitable sealant around
holes of the camshafts and injection pump timing the contact face of the front cover. Fit the front cover
holes. Loosely to the engine and retain in place with a few
If the 3 x (G) cannot be fitted then remove the chain bolts, fitted.
and repeat the procedure, engine timing adjustment. Note: To ensure correct alignment, the cover must be
IMPORTANT: Do not slacken the sprocket bolts free to move on the retaining bolts.
unless the locking pins are fitted. If only the injection Fig.6
pump locking pin will not enter – slacken the 4
sprocket bolts, turn pump shaft nut slightly until the
pin enters, then tighten sprocket bolts.
5. Front Cover Installation
Note: If the front cover is damaged or distorted from
removal, then a new cover should be used.
When installing the engine front cover it must be
correctly positioned relative to the crankshaft using
(A). This ensures that the crankshaft seal located in 5-3 Fit (A) on to the crankshaft and into the engine
the engine front cover is correctly aligned and will not cover, ensuring that it is locating fully in the recess of
wear prematurely. the engine cover.

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Whilst maintaining the position of the cover, fit and IMPORTANT: Fuel line connections and their
fully tighten all nuts and bolts that attach the front surrounding areas must be thoroughly cleaned prior to
cover to the engine. dismantling. All fuel circuit openings should be
Remove (A). blanked off immediately to prevent foreign matter
Fig.7 from entering the fuel system. The components of the
high pressure fuel system may fail prematurely if this
is not observed. Once disconnected, the high pressure
fuel lines that run from the pump to the injectors/fuel
rail should be discarded and replaced.
The engine design allows the injection pump to be
removed and installed without disturbing the engine
timing.
An aperture allowing access to the injection pump
sprocket is provided in the front timing chain cover.
Note: A new oil seal comes with a sleeve to aid Using (C) the sprocket can be held securely in place
fitment over the crankshaft. whilst the pump is removed.
Fig.8 The following instruction does not apply to the 2.2
engines with the H.P. pump driven from the rear of the
inlet camshaft. Removal of the H.P. pump on these
engines does not affect the timing system (no special
tools are required).
For 2.4 TDCi Engines From 2006 With Denso
Common Rail Systems
1. TDDi & TDCi Fuel Systems (NOT Denso)
Note: Highlighted text applies to TDDi fuel systems
only.
5-4 Install the oil seal on to the crankshaft, ensuring 1-1 Assemble (B) with (A).
that the seal retaining tabs are positioned behind the Fig.9
timing cover.
Assemble (B) with (A) and fit into the three holes of
the oil seal. Rotate the seal clockwise until it is
locked in position.
Section 2- Fuel Injection Pump Removal &
Installation
WARNING: Wait a minimum of 15 minutes after
stopping the engine before beginning working the
high pressure fuel system. 1-2 With (B) located into the three holes of the access
Note: If a new injection pump is to be fitted, it must cover, rotate the tools in an anti-clockwise direction to
be configured to the PCM (Powertrain Control remove the pump sprocket cover from the engine
Module) using dealer special equipment. timing cover.

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On engines with TDDi fuel systems it is necessary Apply slight pressure to the end of the pin and turn the
to lock the flywheel in its „timed‟ position before crankshaft slowly and carefully until the pin engages
removing the fuel pump. the slot in the flywheel ring.
On engines with TDCi fuel systems (NOT Denso) The crankshaft is now at 50° BTDC.
it is only necessary to visually position the timing Fig.11
hole in the pump sprocket before removing the fuel
pump.
Fig.10

1-3-3 Assemble (C), (B) with (A).

Fig.12

1-3 Removal
1-3-1 Rotate the engine in the normal direction of
rotation whilst observing the fuel pump sprocket.
Position the timing hole in the pump sprocket to:
TDDi engines - 12 o‟clock 1-3-4 Position the assembled tools through the access
TDCi engines - 1 o‟clock cover aperture and the recess of the pump sprocket,
WARNING: DO NOT use the Flywheel Locking ensuring that the 3 tabs of (C) are positioned behind
Pin to counter-hold the crankshaft when releasing the engine front cover.
or tightening the crank pulley bolt. The flywheel Rotate the assembled tools clockwise until they reach
pin is located through the sensor holder which will the stop position and then remove (A) and (B). The
be damaged if used to restrain the crankshaft. fuel pump sprocket is now secured in position.
DO NOT turn the engine with the flywheel pin WARNING: (C) MUST NOT be removed once the
fitted. fuel pump bolts are released. If the pump sprocket is
1-3-2 Remove the crankshaft position sensor. Insert not secured correctly and moves, the timing cover will
(E) through the sensor holder so it rests on the need to be removed to enable the engine timing and
flywheel ring. chain tensioner to be re-set.

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Remove electrical connections to the fuel pump. 1-4 Installation

Remove all fuel line connections to the pump, 1-4-1 Fit the H.P. pipes to the pump using new
fitting suitable blanking caps that will prevent washers and fit the spacer and new gasket.
foreign matter from entering the fuel system. 1-4-2 TDDi Fuel Systems Only
Fig.13 Fit one of the (G) through the slot in the pump flange
prior to re-locating the pump
.
Clean and apply Loctite (270) to the three pump
securing bolts and re-locate the pump on to the engine,
screw the three bolts finger tight at this stage.
Loosely secure the mounting bracket at the rear of the
pump to the cylinder block.
Fully screw in the four pump sprocket retaining bolts,
1-3-5 Using a Tx45 Drive Bit, locate and release then release them back ¼ turn.
the 3 bolts that secure the injection pump body. Tighten the three injection pump securing bolts using
These bolts are accessed through the 3 holes in (C). a suitable Tx45 Drive Bit to 22 Nm and then fully
Note: These securing bolts cannot be fully removed tighten the sprocket retaining bolts to 32Nm.
and remain in the sprocket throughout this Remove (C) securing the pump sprocket.
procedure. Tighten the four pump mounting bracket bolts to
Fig.14 secure the bracket to pump and cylinder block.
Fig.16

1-3-6 Remove the 4 injection pump sprocket

retaining bolts, releasing the pump from the
sprocket.
At the rear of the pump – slacken the bolts fixing
the pump to its mounting bracket and remove the 1-4-2 TDDi Fuel Systems Only
bolts fixing the bracket to the cylinder block. Remove (G).
Remove the pump, taking care to ensure that the TDDi Fuel Systems Only - Checking Pump Timing
spacer remains on the front flange. Paint mark the crankshaft position on crank pulley and
Fig.15 timing cover.
Remove the Flywheel Locking Pin and turn the engine
over twice, by hand, returning to the paint timing
marks.
Fit (E) into the flywheel sensor ring.
Check that pump timing is correct by ensuring that (G)
can be fully inserted.

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WARNING: DO NOT remove the fuel pump

bolts. If the pump sprocket is not secured correctly
and moves, the timing cover will need to be
removed to enable the engine timing and chain
tensioner to be re-set.
Slacken the four sprocket retaining bolts.
WARNING: DO NOT use the fuel pump nut or
bolts to adjust the timing chain tension.
Tension the timing chain by applying a force in an 2-1-3 Assemble (C), (B) with (A).
anti-clockwise direction to the pump sprocket using Fig.19
a screwdriver.
Tighten the sprocket retaining bolts to 32 Nm and
remove the (G).
Remove (E).
1-4-3 Using (B) with (A), re-fit the pump sprocket
access cover.
2. 2.4 Engines from 2006- Denso Common
Rail System
2-1 Removal 2-1-4 Fit the assembled tools into the access cover
2-1-1 Assemble (B) with (A). aperture and the pump sprocket, and then rotate the
Fig.17 tools clockwise until they reach the stop position. The
fuel pump sprocket is now secured in position.
WARNING: (C) MUST NOT be removed once the
fuel pump bolts are released. If the pump sprocket is
not secured correctly and moves, the timing cover will
need to be removed to enable the engine timing and
chain tensioner to be re-set.
Fig.20
2-1-2 With (B) located into the three holes of the
pump sprocket access cover, rotate the tools
anticlockwise to remove the access cover from the
timing chain cover.
Fig.18

2-1-5 IMPORTANT: If the incorrect bolts are

removed it will not be possible to install (D) correctly.
Ensure that (C) is fitted before releasing sprocket
bolts.

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Remove the two sprocket bolts as shown and the 2-2-2 Refit the central nut to the pump spindle,
central nut from the pump spindle. tightening to 64 Nm.
Remove the electrical connections to the fuel pump. Refit the two sprocket bolts and tighten to 33Nm.
Remove all fuel line connections to the pump, Remove (C) and refit the access cover to the timing
fitting suitable blanking caps that will prevent chain.
foreign matter from entering the fuel system. Reconnect the low pressure fuel lines and electrical
Remove the two securing bolts from the rear of the connections to the fuel pump.
pump. Fit a new H.P. fuel line from the pump to the fuel rail.
Fig.21 Fit both end nuts finger tight, then tighten to a final
torque to 35 Nm.
Using main dealer level special equipment, carry out
the fuel injection pump learning procedure.
Fig.23

Shown without High Pressure Pump Sprocket

Retaining Tool fitted for clarity
2-1-6 Fit (D) and rotate the force screw in a Fuel Injection Pump Sprocket Locking Tool
clockwise direction, pushing the pump out of the Removal
sprocket. WARNING: Make sure that the fuel pressure has
Support the fuel pump during this procedure to dropped to zero and that the fuel temperature is at
prevent it from falling. Remove the fuel pump. ambient temperature.
Remove (D) from the pump sprocket. 1. Use the special tool: 303-679
Fig.22 Fig.24

2-2 Installation
2-2-1 Clean the mating surfaces of the fuel pump
and the engine.
Replace the o-ring oil seal on the fuel pump.
Fit the fuel pump and two securing bolts at rear of
the pump, tightening to 23 Nm.

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2. Install the special tool (I) Fig.27

Fig.25

CAUTION: Make sure that the fuel line remains in

contact at both ends until both union nuts have been
unscrewed and the area around the joints
thoroughly cleaned.
CAUTION: Make sure that all openings are sealed. Installation
Use new blanking caps. 1. Remove the special tool (D).
3. CAUTION: Make sure that all openings are Fig.28
sealed. Use new blanking caps.
Refer to: Quick Release Coupling (310-00 Fuel
System)
Fig.26

2. Torque: 23 Nm
Fig.29

3. Torque: 64 Nm
Fig.30

4. Install the Special Tool (D).

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4. Remove the special tool (I).

Fig.31

5. Special Tool 303-679

Fig.32

6. Refer to: Quick Release Coupling (310-00 Fuel

System)
Fig.33

7. Install the following items:

No.1: Torque: 10 Nm
No.2: Note: Make sure that a new component is
installed.
Torque: Stage 1: 5 Nm, Stage 2: 35 Nm
Fig.34

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