Page 793 of 3229
ItemPart NumberDescription
1-High-pres sure common fuel rail2-Bolt (2 off)
The common fuel rail is manufact ured from forged s teel and is s ecured wi th 2 bolt s to the cyli nder head, above t he li ne oft he exhaus t cams haft . The fuel rai l st ores press uri zed fuel from t he high-pres sure fuel pump and deli vers t he fuel t o thefuel inject ors .
The fuel rai l pres sure is regulat ed by a Pres s ure Cont rol Valve (PCV) l ocat ed at the fuel pump end of the fuel rail , undert he cont rol of the ECM. A fuel pres sure s ensor i ns t alled in t he oppos i te end of t he fuel rai l provides t he act ual fuelpres s ure s ignal to the ECM. For addi ti onal i nformat ion, refer to:
Fuel Charging and Cont rols (303-04B Fuel Charging and Controls - TD4 2.2L Di es el, Des cri pt ion and Operati on),Elect roni c Engi ne Cont rol s (303-14 Electroni c Engi ne Controls - 2.2L Duratorq - Td4, Descri pti on and Operat ion).
Fuel Injectors
Page 794 of 3229

ItemPart NumberDescription
1-Injector mount ing clamp bol t2-Dowel
3-Copper washer
4-Cent ering ring5-Injector
6-Injector mount ing clamp
The 4 pi ezo-el ect ri c operated fuel injectors are cent rall y mounted above each cyl inder combus ti on chamber. Each i njector iss eal ed agai nst the bas e of the injector bore wit h a copper was her. A cent ering ri ng ins tal led over the i njector body makess ure t he i nject or is correct ly pos i ti oned wi thi n t he inject or bore.
• NOTE: A new copper washer mus t be i ns t alled and the ol d was her dis carded, whenever an inject or is removed from t hecyl inder head. The cent eri ng ri ng may be re-us ed duri ng inject or removal.
The inject or pi pes are s i ngl e us e only, and mus t be renewed whenever a pi pe connection is releas ed.
The inject or is s ecured t o t he st ruct ural cams haft cover wit h an i nject or mounti ng cl amp and bolt . A dowel that i s a l oos efi t in the cams haft cover provi des the anchor point for the opposi te end of the i njector mounti ng clamp.
• NOTE: Care must be taken when removi ng the st ruct ural cams haft cover or i njectors to prevent acci dent al los s of theinject or mount ing cl amp dowels .
Operat ion of t he inject ors i s cont rol led direct ly by the ECM. For addi ti onal i nformat ion, refer to:
Fuel Charging and Cont rols (303-04B Fuel Charging and Controls - TD4 2.2L Di es el, Des cri pt ion and Operati on),Elect roni c Engi ne Cont rol s (303-14 Electroni c Engi ne Controls - 2.2L Duratorq - Td4, Descri pti on and Operat ion).
Glow Plugs
Page 795 of 3229
ItemPart NumberDescription
1-Gl ow plug2-Gl ow plug harnes s
The 4 gl ow plugs are ins tal led at t he lower RH s i de of the cyli nder head, adjacent to each i ntake heli cal port . Each gl owplug s eats in a formed dri ll ing wi th the t ip protruding i nt o t he combus t ion chamber. The glow plugs are connect ed by acommon electrical harness , and are cont roll ed by t he ECM.
The glow pl ugs pre-heat t he combus t ion chamber before and duri ng engine cranking t o promot e combus ti on. The glowplugs are ess enti al for aiding engine st art ing, and als o reduce emi s si ons and engi ne noi s e of a cold engine. For addit ionalinformat ion, refer t o:
Elect roni c Engi ne Cont rol s (303-14 Electroni c Engi ne Controls - 2.2L Duratorq - Td4, Descri pti on and Operat ion),Glow Pl ug Syst em (303-07B Gl ow Plug Sys tem, Des cri pt ion and Operati on).
Exhaust Gas Recirculation (EG R) Valve and Cooler Assembly
Page 796 of 3229

ItemPart NumberDescription
1-Fixi ng to cams haft cover2-EGR cooler
3-Bolt (3 off)
4-EGR valveThe EGR valve and cooler ass embl y is l ocat ed on t he RH s ide of t he cylinder head above t he exhaus t manifold, ands ecured wit h 4 fixi ngs . An i nl et pipe connects the EGR cooler t o t he exhaus t manifold. A gas t rans fer t ube is rout ed acros st he engi ne and connect s t he EGR valve out let t o the intake mani fold hous ing.
A pi pe on t he EGR cool er body connect s to the cl imat e cont rol heater outl et hos e, and provides t he cool ant s upply t o t heEGR cooler. The EGR cooler outl et connect s t o t he cool ant rail , locat ed on t he RH s ide of the engine. The cool ant rail isconnected bet ween the t hermal control modul e and the coolant pump rear hous ing.For addit ional informat ion, refer t o: Engi ne Cooling (303-03B Engine Cooli ng - TD4 2.2L Dies el , Descripti on and Operat ion).
The EGR i s cont rol led by t he ECM, and is enabled when t he engine i s at normal operati ng t emperature and under crui si ngcondi ti ons .For addit ional informat ion, refer t o: Engi ne Emis s ion Cont rol (303-08B Engi ne Emis s ion Cont rol - TD4 2.2L Di esel ,Des cript ion and Operat ion).
Intake Manifold
Page 797 of 3229

ItemPart NumberDescription
1-Int ake manifol d2-Bolt (7 off)
The int ake manifol d i s located on t he LH s i de of the engine, and att ached t o t he cylinder head wit h 7 bol ts . The 4 l owerhelical s wirl ports and 4 upper fil ling ports are s ealed t o t he cyl inder head and s tructural cams haft cover wi th a s hapeds eal ing ring. Care must be taken when ins t al li ng the intake mani fold that t he s eal ing rings are correctl y s eat ed wi thi n theport s.
• NOTE: A s mal l quant it y of grease may be us ed t o ret ain t he s ealing rings i n t he int ake manifol d port s duri ng ins tal lati onof the intake mani fold.
The int ake manifol d provides t he l ocati on for t he electronic t hrot tl e ass embl y, and t he port de-act ivati on devi cecomponents . A port on t he RH s ide of t he i nt ake manifold provi des the connect ion for t he EGR gas t rans fer t ube. Foraddi ti onal i nformat ion, refer to:
Elect roni c Engi ne Cont rol s (303-14 Electroni c Engi ne Controls - 2.2L Duratorq - Td4, Descri pti on and Operat ion),Int ake Air Dis t ri but ion and Fi lt ering (303-12B Intake Ai r Dis tributi on and Fil tering - TD4 2.2L Dies el, Des cript ion andOperati on).
Exhaust Manifold
Page 798 of 3229

ItemPart NumberDescription
1-Exhaust mani fold2-St ud and nut (9 off)
3-Turbocharger mounti ng fl ange
4-Spacer (9 off)5-Exhaust heat s hield
6-Exhaust heat s hield fixi ng (4 off)
The exhaus t manifold i s att ached t o t he RH si de of the cyli nder head wi th a gas ket and 9 fixings . Spacers are i ns t alled ont he fi xi ngs to al low for expans ion and contract ion of t he manifold, whil e mai nt aini ng the cl ampi ng loads .
The manifold provi des the mount ing l ocat ion for the Variable Geomet ry Turbocharger (VGT) as s embl y, and a connecti on tot he EGR gas transfer tube. A heat s hi eld i s ins t al led wit h 4 fixings over the exhaust mani fold and VGT t o prot ect ot hercomponents , and t o prevent accidental contact wit h t he hot exhaust component s .
The electroni cal ly controll ed VGT is at t ached t o t he exhaus t manifol d outl et fl ange wit h 3 bolt s . For addit ional informati on,refer to:
Turbocharger (303-04C Fuel Charging and Cont rol s - Turbocharger - TD4 2.2L Dies el, Des cript ion and Operat ion),Engi ne Emis s ion Cont rol (303-08B Engine Emis s ion Control - TD4 2.2L Di esel , Des cri pti on and Operati on),Elect roni c Engi ne Cont rol s (303-14 Electroni c Engi ne Controls - 2.2L Duratorq - Td4, Descri pti on and Operat ion).
LUBRICATION SYSTEM
Page 799 of 3229

The lubricat ion sys tem is a wet s ump, pres sure fed type. The oil lubri cat es t he engine s lidi ng s urfaces , di s si pat es heat,absorbs fuel combus t ion resi due and seal s off t he gap between t he cyl inder and pis ton.
The engi ne is lubri cat ed by a force-fed oil circul at ion sys tem compri si ng a full-fl ow oi l fil ter and cooler ass embly. The oilfi lt er and cooler form an int egral ass embly mount ed on t he LH s i de of the cyli nder block, in clos e proxi mit y t o t he oilpump. Engi ne oil is cooled by the engine cooli ng s ys t em, and eliminates t he requi rement for an addit ional remot elymounted engine oi l cooler.
Oil i s drawn out of t he oil pan and pres s uri zed by the cranks haft dri ven oi l pump. The out put from t he oil pump i s fi lt eredand cool ed before bei ng dis t ribut ed to the cyli nder bl ock mai n oil gall ery. Dri ll ings and galleries connect ed to the mai n oilgallery deli ver pres s uri zed oi l to the cyli nder block and cyl inder head reciprocal component bearings. A dri lli ng above No. 3main bearing cap direct s pres s uri zed oi l to a port at t he rear RH si de of the cyli nder block. The port provides pres s uri zedoil t hrough a banjo connect ion and pi pe to the t urbocharger bearings.
All t he engi ne moving parts are l ubricated by press ure or spl as h oi l. Pres s uri zed oil is al so provided for operat ion of t hehydraulic las h adjus ters and ti ming chain tens ioner.
Oil i s ret urned t o t he oil pan under gravi ty. Large drain holes cas t in the cyli nder head and cyl inder bl ock al low a quickret urn of t he oil .
The lubricat ion sys tem is replenis hed t hrough the oi l fi ll er cap, locat ed on t he engine acous t ic cover. An oil l evel gage islocated on the LH si de of the oi l pan. Two marks at t he end of the gage i ndi cat e t he mini mum and maxi mum oi l levels .The difference between the minimum and maximum marks is approximat ely 1.5 l it ers (1.58 US quarts ) of oil .
Oil Pump
Page 800 of 3229

ItemPart NumberDescription
1-Cyl inder block2-Oil pump
3-Mount ing bol ts (4 off)
4-Pres sure rel ief valve housi ng5-Oil pick up and st rai ner
6-Mount ing bol t (1 off)
7-Oil pump out let port8-Oil pump s upply t o cyli nder block
The rot or type oil pump is l ocat ed bet ween t he oil pan and oil pan housi ng, and is at tached wit h 4 bol ts t o t he rear of t hecount er-bal ance s haft as s embly. A furt her bolt at t he oil s t rainer s ecures the oi l pump to the oi l level gage t ube. The oi lpump s pur gear cont ains 21 teeth and is driven by t he 18 t eet h cranks haft gear, via a 48-li nk s ingle row chain wi thoutt ens ioner.
The oil pick up and s t rai ner prot rude beneath the count er-balance shaft ass embly and are i mmersed i n t he res ervoir of oil .A connect ion between the oi l pump out let , a port i n t he count er-bal ance s haft hous ing, and the cyli nder block direct spres s urized oi l from t he oil pump t o t he oil filt er and cool er as s embly.
The oil pump creat es a maximum oi l press ure of 6.5 bar (94.3 ps i) at 4500 rpm, wit h a deli very rat e capabl e of 50 li ters(53 US quart s) per mi nut e. A pres s ure reli ef val ve wit hin t he oil pump out let prot ect s t he oil pump and l ubricati on s yst emcomponents from s ys tem over-pres s ure. The valve wi ll open at approxi matel y 8 bar (116 ps i) to reli eve excess oi l pres sure,direct ing t he rel ieved oil back int o t he oil pan.
Oil Filter and Cooler Assembly