Motor Ford Ranger PDF

303-01A Engine - 2.
5L Duratec-HE (122kW/165PS) - MI4 2015 - 2016 Ranger ICA
Specifications Procedure revision date: 05/6/2015
Specifications
Engine data
Description Specification
Engine code ENEV
Firing order 1-3-4-2
Emission level Stage II, Stage IV
Displacement 2.5L
No. of cylinders 4
Bore 89 mm
Stroke 100 mm
Cubic capacity 2488.5 cm³
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Compression ratio 9.7 : 1
Power output at 5500 rpm 122 kW (165 PS)
Maximum torque at 1500 rpm 213 Nm
Maximum engine speed (intermittent) 6500 rpm
Maximum engine speed (continuous) 6000 rpm
Idle speed 700 rpm
Number of main bearings 5
Camshaft drive Chain
Oil pressure (hot @ 2,000 rpm) 200-268 kPa (29-39 psi)
Engine weight (without accessory drive components and flexplate or flywheel) 203.8 kg
Engine oil capacity
Description Liters
Initial fill including oil filter 6.7
Service fill including oil filter 6.4
Service fill without oil filter 6
Engine oil
Viscosity Specification
SAE 5W-20 Engine oil WSS-M2C930-A
SAE 5W-20 Engine oil WSS-M2C945-A
SAE 5W-20 Engine oil API-SM
SAE 5W-20 Engine oil API-SN
SAE-5W-30 Engine oil WSS-M2C913-C
SAE-5W-30 Engine oil WSS-M2C913-D
SAE-5W-30 Engine oil WSS-M2C929-A
SAE-5W-30 Engine oil WSS-M2C946-A
SAE-5W-30 Engine oil API-SM
SAE-5W-30 Engine oil API-SN
Cylinder block
Description mm
Cylinder bore diameter 89.0 - 89.03 mm
Cylinder bore maximum out-of-round 0.008 mm
Main bearing bore diameter 57.018 - 57.040 mm
Head gasket surface flatness 0.1 mm/general and 0.05 mm/200 x 200
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Piston
Description mm
Diameter (1) 88.965 - 88.975 mm
Diameter (2) 88.975 - 88.985 mm
Diameter (3) 88.985 - 88.995 mm
Piston-to-bore clearance 0.025 - 0.045 mm
Ring groove width - top 1.203 - 1.205 mm
Ring groove width - 2nd 1.202 - 1.204 mm
Ring groove width - oil 2.501 - 2.503 mm
Piston skirt coating thickness 0.008 - 0.016 mm
Piston pin
Description mm
Diameter 19.995 - 20.0 mm
Length 54.7 - 55.0 mm
Valve
Description mm and degree
Valve head diameter - intake 34.85 - 35.15 mm
Valve head diameter - exhaust 29.85 - 30.15 mm
Valve stem diameter - intake 5.470 - 5.485 mm
Valve stem diameter - exhaust 5.465 - 5.480 mm
Valve stem-to-guide clearance - intake 0.0027 mm
Valve stem-to-guide clearance - exhaust 0.0029 mm
Valve face runout 0.05 mm
Valve face angle 45 degrees
Valve spring - compression pressure
Description kg and mm
Intake and exhaust (installed) 17.5 kg
Intake (valve open) 8.9 mm of lift 44 kg
Exhaust (valve open) 7.4 mm of lift 42 kg
Free length 44.92 mm
Assembled height 37.9 mm
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Cylinder head
Description mm and degree
Cylinder head flatness 0.08 maximum overall, a maximum of 0.05 mm within 150 mm
Valve lift @ zero lash (exhaust) 7.7 mm
Valve lift @ zero lash (intake) 8.8 mm
Valve guide diameter 5.509 - 5.539 mm
Valve seat width - intake/exhaust 0.99 - 1.84 mm
Valve seat angle 45 degrees
Valve seat runout 0.075 mm
Valve lash adjuster bore diameter 31.00 - 31.03 mm
Cam bore diameter 25.015 - 25.040 mm
Crankshaft
Description mm
Main bearing journal diameter 51.978 - 52.002 mm
Production repair 51.730 - 51.750 mm
Main bearing clearance 0.016 - 0.047 mm
Connecting rod journal diameter 51.978 - 52.002 mm
Production repair 51.730 - 51.750 mm
End play 0.220 - 0.450 mm
Rings
Description mm
Width - top 1.17 - 1.185 mm
Width - 2nd 1.197 - 1.199 mm
Width - oil 2.38 - 2.45 mm
Ring gap (in bore) - top 0.16 - 0.26 mm
Ring gap (in bore) - 2nd 0.31 - 0.46 mm
Ring gap (in bore) - oil 0.15 - 0.40 mm
Valve tappet
Description mm
Tappet-to-valve clearance -intake 0.22 - 0.28 mm
Tappet-to-valve clearance -exhaust 0.27 - 0.33 mm
Tappet-to-bore clearance 0.02 - 0.06 mm
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Valve tappet for flex fuel vehicles (FFV)
Description mm
Tappet-to-valve clearance -intake 0.25 - 0.31 mm
Tappet-to-valve clearance -exhaust 0.30 - 0.36 mm
Tappet-to-bore clearance 0.02 - 0.06 mm
Camshaft
Description mm
Intake camshaft lobe lift 8.24999 mm
Exhaust camshaft lobe lift 7.80007 mm
Runout (1)a 0.03 mm
Thrust clearance 0.09 - 0.24 mm
Journal diameter 24.96 - 24.98 mm
Journal-to-bore clearance 0.035 - 0.080 mm
a - No. 3 journal - supported by No. 1 and No. 5 journals.
Connecting rod
Description mm
Bearing clearance 0.027 - 0.052 mm
Bearing thickness 1.496 - 1.520 mm
Crank bore diameter 55.025 - 55.045 mm
Pin bore diameter (with bushing inserted) 20.010 - 20.021 mm
Length (center-to-center) 151.8 mm
Side clearance 1.95 - 3.05 mm
Axial clearance 0.14 - 0.36 mm
Copyright © 2016 Ford Motor Company
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303-01A Engine - 2.5L Duratec-HE (122kW/165PS) - MI4 2015 - 2016 Ranger ICA
Description and Operation Procedure revision date: 05/7/2015
Engine - Component Location
Base Part Number: 6L084
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Item Description
1 Engine front cover
2 Coolant pump
3 Thermostat
4 Intake manifold
5 Oil level indicator
6 Crankcase ventilation oil separator
7 Oil filter and cooler
8 Oil pan
9 Coolant pump pulley
10 Cranksahft pulley
11 Accessory drive belt idler pulley
12 Fuel rail
13 Ignition coils
14 Oil filler cap
15 Valve cover
16 Exhaust manifold
17 Flywheel
18 Water outlet connector
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Engine - Overview
General View
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Item Description
1 Valve cover
2 Cylinder head
3 Cylinder block
4 Oil pan

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Item Description
1 Engine code
2 Engine serial number
Variable camshaft timing (VCT)

Item Description
1 Control unit - variable camshaft timing
2 Camshaft bearing cap
3 VCT oil control solenoid
4 Valve cover
5 Camshaft position sensor
6 Camshaft sensor ring
This system is an electronically controlled camshaft adjuster that allows variable timing for the inlet camshaft.
The valves are driven by a timing chain which drives the inlet camshaft timing control unit. This unit drives the
associated camshafts. The timing chain is tensioned using a conventional timing chain tensioner.
The inlet camshaft is fitted with a sensor ring for the active camshaft position (CMP) sensor.
This CMP sensor is mounted inside the valve cover.
Timing chain replacement does not require the variable camshaft timing control unit to be disconnected.
To ensure trouble-free operation of the variable camshaft timing system and optimum engine performance, it is
essential to adhere precisely to the valve timing adjustment procedure.
A special tool is needed to fix the camshafts in the adjustment position.
Remember that this special tool must not be used to keep the camshaft from rotating when mounting the camshaft
sprocket. They may only be kept from rotating by using the hexagon, which has been specially provided for this
purpose.
Advantages of variable camshaft timing (VCT).
Lower fuel consumption due to improved volumetric efficiency
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Enhanced engine power and torque
Improved idling characteristics
Power and torque curve

Item Description
A Torque curve
B Power curve
C SAE Power (kW)
D Engine speed (rpm)
E SAE torque (Nm)
Service note: (If applicable)
The valve clearance of the engine only needs to be monitored (every 60,000 km) if the engine is converted to
operation using alternative fuel such as LPG, CNG or ethanol blends.
Conversion of the engine to operation with alternative fuel requires no modification to the engine as the valve seats
are reinforced as standard. All that is required is an adaptation of the fuel system.
Valves and valve seats
The engines for petrol operation and LPG/CNG operation are basically identical. Because LPG/CNG is a dry fuel and
combusts at a higher temperature, the valve train is under higher stress. The adaptations described below are
therefore necessary.
Because of the higher stress involved in LPG/CNG operation:
The inlet valves are made of a harder material.
The inlet and exhaust valve seats are made of a harder material.
The valve clearances must be checked and corrected if necessary.
Lubrication System
The engine lubrication system operates as follows:
Oil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the oil pan.
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Oil is pumped through the oil filter on the right front side of the cylinder block.
Oil enters the main gallery where it is distributed to the crankshaft main journals and to the cylinder head.
From the main journals, the oil is routed through cross-drilled passages in the crankshaft to lubricate the
connecting rod bearings. Controlled leakage through the crankshaft main bearings and connecting rod bearings
is slung radially outward to cool and lubricate the cylinder walls as well as the entire connecting rod, piston and
piston ring assembly.
Diagnosis and Testing Procedure revision date: 02/22/2015
Engine
1. For basic mechanical concerns.
REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
For driveability concerns. Refer to Powertrain Control/Emissions Diagnosis (PC/ED) manual.
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General Procedures Procedure revision date: 10/28/2013
Valve Clearance Adjustment
Materials
Name Specification
Engine Oil - SAE 5W-30 WSS-M2C913-C

Check
1. Refer to: Valve Cover (303-01A Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation).
2. NOTICE: Only rotate the crankshaft clockwise.
Rotate the crankshaft until the cam pair of the cylinder to be adjusted are pointing upwards. Using a suitable
feeler gauge, measure the valave clearance.
3. Make a note of each cylinder number with the corresponding valve clearance.
4. Compare the measured valve clearance(s) with the specifications.
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Refer to: Specifications (303-01A Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Specifications).

Adjustment
1. NOTE: Only carry out the following steps when the valve clearance(s) require adjustment.
2. Refer to: Timing Chain (303-01A Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation).
3. NOTICE: Note the position of each component before removal.

Remove the valve tappet and read the thickness from the underside.
The number on the valve tappet indicates the thickness of the bottom of the tappet. However, the
number only indicates the digits after the decimal point (example: .650 = 3,650).
Calculate the required thickness of the valve tappet with the following formula: X = S + M - V
Required thickness of tappet = X
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Thickness of currently fitted tappet = S
Measurement of existing valve clearance (actual value) = M
Desired valve clearance = V
6. Install the correct valve tappet.
7. NOTICE: Make sure that the camshafts and camshaft bearing caps are installed in their original
locations.
Coat the camshaft bearing caps with oil.
Material: Engine Oil - SAE 5W-30 (WSS-M2C913-C)
8. Install the camshafts approximately at valve overlap position cylinder No. 4.
Torque:
Stage 1: 7 Nm
Stage 2: 16 Nm

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Removal and Installation Procedure revision date: 06/23/2016
Camshafts
Special Tool(s) / General Equipment
303-465
Tool, Camshaft Align Timing
303-507
Timing Peg, Crankshaft TDC
2 mm Punch
Materials
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Name Specification
Gear/Transmission Fluid - SAE 85W-90 SQ-M2C9002-AA

Thread Locking Adhesive WSK-M2G349-A7

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Accessory Drive Belt (303-05A Accessory Drive - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal
and Installation).
Turn the crankshaft until no. 1 piston is at about 45° before TDC.

4. NOTE: The camshaft timing slots are offset. If the camshaft alignment plate cannot be installed, rotate the
crankshaft one complete revolution clockwise to correctly position the camshafts.
Use Special Service Tool: 303-465 Tool, Camshaft Align Timing.

5.
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6. Use Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

7. NOTE: Only tighten the bolt finger tight at this stage.
Bolt M6 x 18 mm

8.
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9. Reposition the camshaft alignment plate to the slot on the rear of the intake camshaft only.

10. NOTE: To hold the tensioner arm in a retracted position and allow enough slack in the timing chain for removal
of the exhaust camshaft gear,, install an M6 x 25 mm bolt into the upper front cover timing hole.
1. Use the General Equipment: 2 mm Punch
3. Bolt M6 x 25 mm
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11. NOTICE: Use an open-ended wrench to prevent the component from turning..

12. Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing.

13. Remove the timing chain from the intake camshaft drive gear.
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14. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.

15. NOTE: Note the position of the components before removal.

Installation
1. NOTE: Make sure that the components are installed to the position noted before removal.
NOTE: Lubricate the components with clean engine oil..
Coat the camshaft bearing caps with oil and install the camshafts approximately at valve overlap position
cylinder No. 4.
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Material: Gear/Transmission Fluid - SAE 85W-90 (SQ-M2C9002-AA)
Torque:
Stage 1: 7 Nm
Stage 2: 16 Nm

2. NOTE: This step is only necessary when installing a new component.
Refer to: Valve Clearance Adjustment (303-01A Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, General
Procedures).
3. Install the timing chain on the intake camshaft drive gear.

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5. NOTE: Releasing the tensioner arm will remove the slack from the timing chain..
Remove the bolt M6 x 30mm.

6. NOTICE: Use an open-ended wrench to prevent the component from turning.
Torque: 72 Nm

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8. Remove the bolt M6 x 18 mm.

9. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

Material: Thread Locking Adhesive (WSK-M2G349-A7)
1. Torque: 10 Nm
2. Torque: 12 Nm
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11. Torque: 20 Nm

and Installation).
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Crankshaft Front Seal
Base Part Number: 6700
303-318
Aligner/Installer, Crankshaft Front Seal
303-409 (T92C-6700-CH)
Remover, Crankshaft Seal
Removal
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1. Refer to: Crankshaft Pulley (303-01A Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and
Installation).
2. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.

Installation
1. Use Special Service Tool: 303-318 Aligner/Installer, Crankshaft Front Seal.

2. Remove Special Service Tool: 303-318 Aligner/Installer, Crankshaft Front Seal.
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3. To install, reverse the removal procedure.
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Crankshaft Pulley
303-1416
Tool, Crank Damper Holding
303-465
303-507
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Removal
and Installation).
Turn the crankshaft until no. 1 piston is at about 45° before TDC.

4. Use Special Service Tool: 303-1416 Tool, Crank Damper Holding.

Installation
Turn the camshafts to cylinder no. 4 valve overlap position.
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2. Use Special Service Tool: 303-465 Tool, Camshaft Align Timing.

3.

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Turn the crankshaft until it stops against the special tool.

6.

M6 x 18 mm.
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8. NOTICE: Make sure that a new bolt is installed.
Use Special Service Tool: 303-1416 Tool, Crank Damper Holding.
Torque:
Stage 1: 100 Nm
Stage 2: 90°

9.

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Turn the crankshaft one and three quarters of a turn until no. 1 piston is at about 45° before TDC.

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Turn the crankshaft until it stops against the special tool.

NOTE: The bolt can only be installed if the valve timing is correct.
M6 x 18 mm.

16. NOTE: The special tool can only be installed if the valve timing is correct.
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19. M6 x 18 mm.
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20. Torque: 20 Nm

21. To install reverse the removal procedure.
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Crankshaft Rear Seal
303-254
Locking Tool, Flywheel
303-328 (T88P-6701-B1)
Replacer, Rear Seal
Removal
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1. Refer to: Clutch Disc and Pressure Plate (308-01A Clutch - 5-Speed Manual Transmission - MT75, Removal
and Installation).
2. Use Special Service Tool: 303-254 Locking Tool, Flywheel.
Torque:
Stage 1: 50 Nm
Stage 2: 80 Nm
Stage 3: 112 Nm

3. Refer to: Oil Pan (303-01A Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation).
4.

Installation
1. NOTE: Make sure that a new component is installed.
Use Special Service Tool: 303-328 (T88P-6701-B1) Replacer, Rear Seal.
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2. Use Special Service Tool: 303-328 (T88P-6701-B1) Replacer, Rear Seal.
Torque: 10 Nm

3. Remove Special Service Tool: 303-328 (T88P-6701-B1) Replacer, Rear Seal.

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Cylinder Head
Materials
Name Specification

Removal
1. Refer to: Cooling System Draining, Filling and Bleeding (303-03A Engine Cooling - 2.5L Duratec-HE
(122kW/165PS) - MI4, General Procedures).
3.
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4.

5. Torque: 10 Nm

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6. NOTICE: Over bending the exhaust flexible pipe may cause damage resulting in failure.
NOTICE: Make sure that the catalytic converter is supported with suitable retaining straps.
NOTE: The gasket is to be reused unless damaged.
Torque: 48 Nm

7. Torque: 48 Nm

8.
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9.

10. Torque: 23 Nm

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11. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.

12. NOTICE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
NOTICE: Note the position of each component before removal.
NOTE: Mark the location and orientation of each camshaft bearing cap.

13. Discard the cylinder head bolts.
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Installation
1. Install new cylinder head bolts.
Torque:
Stage 1: 5 Nm
Stage 2: 15 Nm
Stage 3: 45 Nm
Stage 4: 90°
Stage 5: 90°

locations.
Apply hypoid gear oil to the camshaft bearing caps. Install the camshafts approximately at valve overlap
position cylinder No. 4.
Torque:
Stage 1: 7 Nm
Stage 2: 16 Nm

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3. To install reverse the removal procedure.
Engine Front Cover
Base Part Number: 6C086
303-1417
Tool, Crank Sensor Alignment
Materials
Name Specification
Silicone Sealant WSE-M4G323-A4

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Removal
1. Loosen: 3 turn(s)

2.

3. Refer to: Crankshaft Pulley (303-01A Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and
Installation).
Vehicles With: Hydraulic Power Assist Steering (HPAS)
4. Torque: 20 Nm
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Vehicles With: Electronic Power Assist Steering (EPAS)
5. Torque: 25 Nm

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All vehicles
1. Torque: 25 Nm
2. Torque: 20 Nm

7.
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Installation
1. NOTICE: Install the engine front cover within five minutes of applying the sealer.
NOTE: Do not damage the mating faces.
NOTE: Mating surface should not have traces of oil to improve the adhesion.
Apply sealant to the engine front cover (bead diameter: 3 mm).
Material: Silicone Sealant (WSE-M4G323-A4)
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2. Torque:
1 - 8: 10 Nm
9: 48 Nm
10 - 19: 10 Nm
20 - 22: 48 Nm
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4. Use Special Service Tool: 303-1417 Tool, Crank Sensor Alignment.

5. Torque: 7 Nm

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Exhaust Manifold
Removal
1. Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
2. Torque: 10 Nm
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3. NOTICE: Make sure that the exhaust flexible pipe is not forcibly bent or twisted.

If equipped.
1. Torque: 48 Nm
2. Torque: 25 Nm

If equipped.
1. Torque: 48 Nm
2. Torque: 25 Nm
3. Torque: 26 Nm
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6.

7.

Installation
1. Torque: 17 Nm
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2. Torque: 55 Nm

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Intake Manifold
Removal
1. WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working
on or near any fuel-related component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio
equipment of any type when working on or near any fuel-related component. Highly flammable mixtures
are always present and may be ignited. Failure to follow these instructions may result in serious
personal injury.
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always
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present and may be ignited. Failure to follow these instructions may result in serious personal injury.
Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
3. Refer to: Throttle Body (303-04A Fuel Charging and Controls - 2.5L Duratec-HE (122kW/165PS) - MI4,
Removal and Installation).
4. Refer to: Fuel System Pressure Release (310-00A Fuel System - General Information - 2.5L Duratec-HE
5. Torque: 10 Nm
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6. NOTE: Securely strap the fuel and breather tubes.
Torque: 8 Nm

7.

8.
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9. Torque: 11 Nm

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10. NOTE: The gasket is to be reused unless damage.
Torque: 19 Nm

Installation
1. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the
sealing surfaces. These tools can cause scratches and gouges which can make leak paths. Use a plastic
scraping tool to remove all traces of the old intake manifold gaskets.
NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston
damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold.
Failure to follow these instructions can result in engine damage.
3. NOTE: Make sure that the pedals remain in the rest position.
Turn the ignition key to position II and then wait one minute in order to initialise the throttle valve.
4. Turn the ignition key to the OFF position.
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Timing Chain
100-010
Remover, O-Ring Seal
303-465
2 mm Punch
Removal
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1. Refer to: Engine Front Cover (303-01A Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and
Installation).
2. Use Special Service Tool: 100-010 Remover, O-Ring Seal.

3.

4. Remove the timing chain tensioner arm.
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5.

Installation
1. NOTICE: Only rotate the camshaft clockwise.
Turn the camshafts to cylinder no. 4 valve overlap position.

2. Torque: 10 Nm
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3.

4. Torque: 10 Nm

5. Refer to: Engine Front Cover (303-01A Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and
Installation).
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Oil Pan
303-290-01
Adapter for 303-290A
303-290-03A
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303-290B
Support Bar, Engine
303-428
Separator, Oil Pan
Materials
Name Specification

Removal
1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
3. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
4.

4x4
5.
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All vehicles
6. NOTE: Be prepared to collect escaping fluids.
NOTE: The seal is to be reused unless damaged.
Drain the oil into a suitable container.

7.

4x4
9. Refer to: Differential Draining and Filling (205-03 Front Drive Axle/Differential, General Procedures).
10. Refer to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation).
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11.

All vehicles
12. On both sides.

13. Lower the vehicle.
14.

15. Refer to: Cooling Fan Motor and Shroud (303-03A Engine Cooling - 2.5L Duratec-HE (122kW/165PS) - MI4,
16. Install the special tools and lift the engine to 60mm approximately.
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Install Special Service Tool: 303-290-01 Adapter for 303-290A. , 303-290B Support Bar, Engine. , 303-290-03A
Adapter for 303-290A.

17. Raise the vehicle.
18.

19.
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20. Use Special Service Tool: 303-428 Separator, Oil Pan.

21.

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Installation

2. NOTICE: Take extra care not to damage the mating faces.
NOTE: The component must be installed within 5 minutes of applying the sealant.
NOTE: Make sure that the mating faces are clean and free of foreign material.

3. NOTICE: Take extra care not to damage the mating faces. .
NOTE: The component must be installed within 5 minutes of applying the sealant.
NOTE: Make sure that the mating faces are clean and free of foreign material..
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4. Torque: 25 Nm

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5. Torque: 10 Nm

6. Torque: 48 Nm

4x4
7. Material: WSS-M4G323-A8

1. Torque: 70 Nm
2. Torque: 40 Nm
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All vehicles
11. Torque: 80 Nm

13. Remove Special Service Tool: 303-290B Support Bar, Engine. , 303-290-01 Adapter for 303-290A. , 303-290-
03A Adapter for 303-290A.

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14. Refer to: Cooling Fan Motor and Shroud (303-03A Engine Cooling - 2.5L Duratec-HE (122kW/165PS) - MI4,
15.

17. Torque: 10 Nm

18. Torque: 28 Nm
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4x4
19. Torque: 30 Nm

All vehicles
20. Torque: 30 Nm

21. Install the front wheels.
Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
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24. Fill the oil pan with clean engine oil.
Refer to: Specifications (303-01A Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Specifications).
Oil Pump
Removal
2. Refer to: Oil Pan (303-01A Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation).
3. NOTICE: Make sure that a new friction washer is installed.
1. Torque: 10 Nm
2. Torque: 25 Nm
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4. Remove the 2 bolts and the oil pump screen and pickup tube.
Torque: 10 Nm
5. Torque:
Stage 1: 10 Nm
Stage 2: 20 Nm

Installation
1. To install, reverse removal procedure.
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Valve Cover
Materials
Name Specification

Removal
1. WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working
on or near any fuel-related component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio
equipment of any type when working on or near any fuel-related component. Highly flammable mixtures
are always present and may be ignited. Failure to follow these instructions may result in serious
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personal injury.
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always
present and may be ignited. Failure to follow these instructions may result in serious personal injury.
4. Torque: 11 Nm

5. Torque: 10 Nm
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6. NOTE: Securely strap the fuel and breather tubes.
Torque: 8 Nm

7.

8.
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9. Torque: 11 Nm

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10. Torque: 19 Nm

11.

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12. Torque: 8 Nm

13.

Installation
1. NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is
not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface
prep.

2. NOTE: The gasket is to be reused unless damaged.
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Torque: 10 Nm

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Valve Stem Seals
303-361B
Compressor, Valve Spring
303-361B-06
Adapter for 303-361B
303-362
Installer, Valve Stem Collets
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303-508
Pliers, Valve Stem Seal
Removal
1. Refer to: Camshafts (303-01A Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation).
2.

3. Use Special Service Tool: 303-361B Compressor, Valve Spring. , 303-361B-06 Adapter for 303-361B. , 303-
362 Installer, Valve Stem Collets.

4. Use Special Service Tool: 303-508 Pliers, Valve Stem Seal.
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Installation
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Removal Procedure revision date: 06/21/2016
Engine Accessories
303-122
Lifting Bracket, Engine
303-254
303-435
Mounting Stand
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303-435-06
Mounting Bracket for 303-435
303-435-14B
Mounting Plate for 303-435-06
Floor Crane
All vehicles
1. Use Special Service Tool: 303-122 Lifting Bracket, Engine.
Use the General Equipment: Floor Crane

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2. Use Special Service Tool: 303-435 Mounting Stand. , 303-435-06 Mounting Bracket for 303-435. , 303-435-
14B Mounting Plate for 303-435-06.


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4. NOTICE: Loosen the clutch pressure plate retaining bolts by two turns at a time in the sequence shown.


6. At this stage Lossen two turns.
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7. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt.

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8. NOTICE: Take extra care not to damage the wiring harnesses.

9.

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12.

13.
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14.

15.

16.
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17.

18.

19.
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20.

21.

22.
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23.

24.

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25.

26.

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All vehicles
27.

28.

29.

30.
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4x2
31.

4x4
32.

All vehicles
33.
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Engine - 5-Speed Manual Transmission - MT75
303-122
Floor Crane
Transmission Jack
1. Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
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4. Refer to: Starter Motor (303-06A Starting System - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and
Installation).
5. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System -
General Information, General Procedures).
7.

8. Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).
9. Refer to: Cowl Panel (501-02 Front End Body Panels, Removal and Installation).
10.

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11.

12.

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13.

14.

15.

16.
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17. WARNING: Be prepared to collect escaping fluids.
NOTICE: Make sure that all openings are sealed.

18.

All vehicles
19.
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20.

21.

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23.

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24.

25. WARNING: Make sure that transmission assembly is on wooden blocks and secured with suitable
retaining straps.
NOTICE: Do not tilt the transmission. This may cause damage to the pilot bearing.
Use the General Equipment: Transmission Jack

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26.

27.

28.

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29.

30.

31.

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33.

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Disassembly Procedure revision date: 06/24/2016
Engine
100-010
303-1416
303-409 (T92C-6700-CH)
Remover, Crankshaft Seal
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303-428
Separator, Oil Pan
303-462
Installer, Connecting Rod
303-465
303-507
2 mm Punch
1.

Rotate the crankshaft until piston No. 1 is approximately 45 degrees before top dead center (TDC).
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4.

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6. Use Special Service Tool: 303-1416 Tool, Crank Damper Holding.

7. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.

8. Discard the friction washer.
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9.
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Use the General Equipment: 2 mm Punch

11.

12. Remove the RH timing chain guide.
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13. Remove the timing chain.

Remove the bolt and the exhaust camshaft sprocket.

Remove the bolt and the camshaft phaser and sprocket.
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17. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.

18. Remove the bolt and the VCT solenoid.
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19. Remove the plug and the VCT system oil filter from the intake camshaft thrust cap.

20. NOTICE: Failure to follow this procedure may result in damage to the components.
NOTE: Mark the location and orientation of each component..

21. NOTE: Note the position of the components before removal.
NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet
with the number 0.650 has the thickness of 3.650 mm.
Remove and inspect the valve tappets.
22. Discard the cylinder head bolts.
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23. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the
cylinder block distortion.
Refer to: Cylinder Head Distortion (303-00 Engine System - General Information, General Procedures).
Refer to: Cylinder Block Distortion (303-00 Engine System - General Information, General Procedures).
24. Remove the cylinder head alignment dowels.

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26.

27. Remove the bolts, oil pump pickup tube and discard the gasket.

28.
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29. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the crankshaft TDC
timing peg.
Use Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

30. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon
deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's instructions.
31. NOTE: Note the position of the components before removal

32. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Using the connecting rod installer, remove the piston or rod assembly from the engine block.
Use Special Service Tool: 303-462 Installer, Connecting Rod.
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33. NOTE: Note the position of each component before removal.

34. Repeat the previous 2 steps until all the piston or rod assemblies are removed from the engine block.
35. Discard the bolts.

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37. NOTICE: Make sure that the balance shaft oil feed plug remain installed in the cylinder block.

38. NOTE: If the components are to be reused, make sure that they are installed to the position noted before
removal

39. NOTE: If the main bearings are being reused,Note the position of the components before removal..
NOTE: The thrust bearing is located in the center bulkhead.
Remove the main bearings from the cylinder block.
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40. NOTE: If the components are to be reused, make sure that they are installed to the position noted before
removal..
NOTE: The front bulkhead does not have an oil squirter.
Remove the 4 oil squirters.

41. Inspect the cylinder block, main bearing beam, pistons and connecting rods.
Refer to: Piston Inspection (303-00 Engine System - General Information, General Procedures).
Refer to: Bearing Inspection (303-00 Engine System - General Information, General Procedures).
Refer to: Connecting Rod Large End Bore (303-00 Engine System - General Information, General Procedures).
Refer to: Cylinder Block Distortion (303-00 Engine System - General Information, General Procedures).
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Disassembly and Assembly of Subassemblies Procedure revision date: 05/12/2015
Cylinder Head
303-361B
303-361B-06
Adapter for 303-361B
303-362
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303-508
DISASSEMBLY
NOTE: Disassembly steps in this procedure may contain assembly details.
1. Refer to: Cylinder Head (303-01A Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation).
1. Torque: 10 Nm
2. Torque: 48 Nm

1. Torque: 25 Nm
2. Torque: 17 Nm
3. Torque: 45 Nm

4.
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5. Use Special Service Tool: 303-361B Compressor, Valve Spring. , 303-361B-06 Adapter for 303-361B. , 303-
362 Installer, Valve Stem Collets.


ASSEMBLY
1. To assemble, reverse the disassembly procedure.
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Assembly Procedure revision date: 07/9/2015
Engine
100-002 (TOOL-4201-C)
Holding Fixture with Dial Indicator Gauge
303-1416
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303-318
Aligner/Installer, Crankshaft Front Seal
303-328 (T88P-6701-B1)
Replacer, Rear Seal
303-462
Installer, Connecting Rod
303-465
303-507
303-D032 (D81L-6002-C)
Compressor, Piston Ring
Materials
Name Specification


1. NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as
instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to
the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction,
using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket
is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the
crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service
tools, otherwise severe engine damage may occur.
NOTICE: During engine repair procedures, cleanliness is extremely important. All parts must be
thoroughly cleaned and any foreign material, including any material created while cleaning gasket
surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.
NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine
block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in
determining if the engine components will require replacement.
2. NOTE: If the oil squirters are being reused, they must be installed in the same location as marked during
disassembly.
NOTE: The front bulkhead does not have an oil squirter.
Install the 4 oil squirters.
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Torque: 4 Nm

3. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest
diameter for each journal.

4. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear
face of the engine block.

5. Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts.
Torque:
Stage 1: 5 Nm
Stage 2: 25 Nm
Stage 3: 90 °
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Measure each crankshaft block main bearing bore diameter.
Remove the bolts and the main bearing beam.
Discard the main bearing beam bolts.

7. Using the chart, select the crankshaft main bearings.

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8. NOTICE: The rod cap installation must keep the same orientation as marked during disassembly or
engine damage may occur.
Using the original connecting rod cap bolts, install the connecting caps and bolts.
Torque:
Stage 1: 29 Nm
Stage 2: 90 °

Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each
connecting rod.
Remove the bolts and the connecting rod cap.
Discard the connecting rod cap bolts.

10. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the
smallest measurement for each connecting rod journal.
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11. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.

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12. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign
material. Also, make sure the coolant and oil passages are clear.
NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted
during disassembly.
NOTE: The center bulkhead is the thrust bearing.
NOTE: Make sure that these components are installed to the noted removal position.
Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in
the cylinder block.

13. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted
during disassembly.
Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the
main bearing beam.

14. Lubricate journals on the crankshaft with clean engine oil.
15. Position the crankshaft in the cylinder block.
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16. Lubricate the 10 main bearing beam side fit surfaces (front 2 shown) with clean engine oil.

17. Lubricate the crankshaft bearing journals on the main bearing beam with clean engine oil. Then position the
main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the
engine block.

18. NOTICE: Make sure that new bolts are installed.
NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil.
NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the
cylinder block before tightening the main bearing beam bolts.
Torque:
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Stage 1: 5 Nm
Stage 2: 25 Nm
Stage 3: 90°

Using the dial indicator gauge with holding fixture, measure crankshaft end play.
Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
Position the crankshaft to the rear of the cylinder block.
Zero the dial indicator gauge with holding fixture.
Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
Acceptable crankshaft end play is 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play exceeds the
specified range, install new parts as necessary.

20. NOTICE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push
the piston down until the connecting rod bearing seats on the crankshaft journal.
NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean
engine oil.
NOTE: Make sure the piston arrow on top is facing toward the front of the engine.
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Using the piston ring compressor and the connecting rod installer, install the piston and connecting rod
assemblies.
Use Special Service Tool: 303-D032 (D81L-6002-C) Compressor, Piston Ring. , 303-462 Installer,
Connecting Rod.
When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60
degrees apart from each other and a minimum of 90 degrees from the expander gap.
The position of the upper and lower compression ring gaps are not controlled for installation.
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21. NOTICE: The rod cap installation must keep the same orientation as marked during disassembly or
engine damage may occur.
NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten.
Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders
2 and 3 and tighten.
NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation.
Install the connecting rod caps and the new bolts.
Torque:
Stage 1: 29 Nm
Stage 2: 90 °

22. NOTICE: Failure to position the No. 1 piston at TDC can result in damage to the engine. Turn the
engine in the normal direction of rotation only.
Turn the crankshaft clockwise to position the No. 1 piston at TDC.
23. NOTE: The crankshaft TDC timing peg will contact the crankshaft and prevent it from turning past TDC.
However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at
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the TDC position until the timing drive components and crankshaft pulley are installed. Install the crankshaft
TDC timing peg.
Install the crankshaft TDC timing peg.
Use Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

24. NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface prep.
Torque:
Stage 1: 10 Nm
Stage 2: 20 Nm

25. Install a new oil pump pickup tube gasket and the pickup tube.
Torque: 10 Nm
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26. NOTICE: Install the crankshaft rear seal carriers within five minutes of applying the sealer.

27. NOTE: New crankshaft rear seal carriers are supplied with an alignment sleeve which must be removed after
installation.
Use Special Service Tool: 303-328 (T88P-6701-B1) Replacer, Rear Seal.
Torque: 10 Nm

28. Remove Special Service Tool: 303-328 (T88P-6701-B1) Replacer, Rear Seal.
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29. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to
clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a
plastic scraping tool to remove traces of sealant.
Clean and inspect all mating surfaces.
30. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine
block.
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31. NOTICE: Install the oil pan within five minutes of applying the sealer.


33. Install the oil pan.
Torque: 25 Nm
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Install the cylinder head alignment dowels.
Dowels must be fully seated in the cylinder block.

35. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to
clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic
scraping tool to remove all traces of the head gasket.
NOTE: Observe all warnings and cautions and follow all application directions contained on the packaging of
the silicone gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the
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surfaces.
Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block
in the following sequence.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket
remover may be required if residual traces of silicone or gasket material remain.
4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to
prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some
staining of the metal surfaces is normal.
36. Apply silicone gasket and sealant to the locations shown.

37. Install a new head gasket.

NOTE: The cylinder head bolts are torque-to-yield and must not be reused.
NOTE: Lubricate the bolts with clean engine oil prior to installation.
Torque:
Stage 1: 5 Nm
Stage 2: 15 Nm
Stage 3: 45 Nm
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Stage 4: 90°
Stage 5: 90°

39. NOTE: Coat the valve tappets with clean engine oil prior to installation.
Install the valve tappets.
locations.
NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
Install the camshafts approximately at valve overlap position cylinder No. 4 and tighten the camshaft bearing
cap bolts one at a time until finger-tight.
Torque:
Stage 1: 7 Nm
Stage 2: 16 Nm

41. Install the variable camshaft timing (VCT) system oil filter and the plug in the intake camshaft thrust cap.
Torque: 17 Nm
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42. Install the VCT solenoid and the bolt.
Torque: 10 Nm

43. NOTE: Install a new crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.
Install the crankshaft sprocket, new crankshaft sprocket diamond washers, oil pump chain and oil pump
sprocket.
The crankshaft sprocket flange must be facing away from the engine block.

1. Torque: 10 Nm
2. Torque: 25 Nm
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46. NOTE: Hand tighten the bolts at this stage.
Install the camshaft sprockets and the bolts.

47. Install the timing chain guide and the bolts.
Torque: 10 Nm
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48. Install the timing chain.

49. NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position,
follow the next 4 steps.
Install the timing chain guide.

50. NOTICE: Do not compress the ratchet assembly. This will damage the ratchet assembly.
Using the edge of a vise, compress the timing chain tensioner plunger.
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51. Using a small pick, push back and hold the ratchet mechanism.

52. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

53. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during
installation.
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54. Install the timing chain tensioner and the bolts.
Torque: 10 Nm

55. NOTICE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts
from turning.
Torque: 72 Nm

56. NOTICE: Install the engine front cover within five minutes of applying the sealer.
NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the
silicone gasket and sealant.
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57. Torque:
1 - 8: 10 Nm
9: 48 Nm
10 - 19: 10 Nm
20 - 22: 48 Nm
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59. Use Special Service Tool: 303-318 Aligner/Installer, Crankshaft Front Seal.
Torque: 50 Nm

60. Remove Special Service Tool: 303-318 Aligner/Installer, Crankshaft Front Seal.
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61. NOTE: Hand tighten the bolt at this stage.
Bolt M6 x 18 mm

62. NOTICE: Make sure that a new bolt is installed.
Use Special Service Tool: 303-1416 Tool, Crank Damper Holding.
Torque:
Stage 1: 100 Nm
Stage 2: 90°

63. Remove the 6 mm x 18 mm bolt.
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65. Install the engine plug bolt.
Torque: 20 Nm

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67. NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is
not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface
prep.

Torque: 10 Nm

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Installation Procedure revision date: 05/6/2015
303-122
Floor Crane
Transmission Jack
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2. NOTE: Hand tighten at this stage.

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6. Torque: 48 Nm
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7. Torque: 48 Nm

8. Torque: 48 Nm

9. Torque: 48 Nm
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10. Torque: 80 Nm

11. Torque: 80 Nm

12. NOTE: Remove the tool
Use Special Service Tool: 303-122 Lifting Bracket, Engine.
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13. Torque: 30 Nm

retaining straps.
NOTE: Remove transmission jack.
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15.

Torque: 10 Nm
Torque: 10 Nm

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1. Torque: 48 Nm
2. Torque: 25 Nm

18. Torque: 10 Nm

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19.

20. Torque: 11 Nm

21.

NOTICE: Make sure that all openings are sealed.
Torque: 35 Nm
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All vehicles
23.

24. Torque: 23 Nm

25.
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26.

1. Torque: 11 Nm
2. Torque: 3 Nm

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28.

29. Torque: 10 Nm

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32. Torque: 30 Nm

35. Refer to: Starter Motor (303-06A Starting System - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and
Installation).
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Engine Accessories
303-122
303-1417
Tool, Crank Sensor Alignment
303-254
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303-435
Mounting Stand
303-435-06
303-435-14B
308-204
Aligner, Clutch Disc
Floor Crane
All vehicles
1. Torque: 48 Nm

4x4
2. Torque: 25 Nm
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4x2
3. Torque: 25 Nm

All vehicles
4. Torque: 25 Nm

Torque: 10 Nm
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Torque: 10 Nm

7.

8.
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9. NOTE: Make sure that the mating faces are clean and free of foreign material.
Torque: 25 Nm

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All vehicles
1. Torque: 25 Nm
2. NOTE: Install all the bolts finger tight before final tightening.

11. Torque: 17 Nm

12. NOTE: Make sure that a new exhaust manifold gasket is installed.
Torque: 55 Nm
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13. NOTE: The accessory drive belt tensioner must be replaced as a complete unit.
Torque: 25 Nm

14. Torque: 8 Nm

15. Torque: 23 Nm
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16.

17. Torque: 10 Nm

18.
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19. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the
sealing surfaces. These tools can cause scratches and gouges which can make leak paths. Use a plastic
scraping tool to remove all traces of the old intake manifold gaskets.
NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston
damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold.
Failure to follow these instructions can result in engine damage.
NOTE: The gasket is to be reused unless damage.
Clean the sealing surfaces and inspect the gaskets. Install new gaskets if necessary.
Torque: 19 Nm

20. Torque: 20 Nm
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21.

22.

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23. Use Special Service Tool: 303-1417 Tool, Crank Sensor Alignment.

24. Torque: 7 Nm

1. Torque: 25 Nm
2. Torque: 10 Nm
3. Torque: 48 Nm

26.
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27.

28.

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1. Torque: 48 Nm
2. Torque: 15 Nm
3. Torque: 48 Nm

30. Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt.

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31. Torque: 20 Nm

Torque:
Stage 1: 50 Nm
Stage 2: 80 Nm
Stage 3: 112 Nm

33. NOTE: The cone on the special tool must only be tightened finger tight to prevent damage to the clutch disc.
Use Special Service Tool: 308-204 Aligner, Clutch Disc.
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34. NOTE: Check the pilot bearing for damage. Replace it, if necessary.
Refer to: Pilot Bearing - 2.5L Duratec-HE (122kW/165PS) - MI4 (308-01A Clutch - 5-Speed Manual
Transmission - MT75, Removal and Installation).

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36. Use Special Service Tool: 308-204 Aligner, Clutch Disc.
Torque: 30 Nm

37. Remove Special Service Tool: 308-204 Aligner, Clutch Disc.

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38. Remove Special Service Tool: 303-254 Locking Tool, Flywheel.


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40. Remove Special Service Tool: 303-435 Mounting Stand. , 303-435-06 Mounting Bracket for 303-435. , 303-
435-14B Mounting Plate for 303-435-06.

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303-01B Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - 2015 - 2016
Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/2.2L Duratorq-TDCi (118kW/160PS) - Puma Ranger ICA
Procedure revision
Specifications date: 08/20/2015
Specifications
Engine Data — 130 PS
Description
Code GBVAJQW
Bore diameter 86 mm
Stroke 94.6 mm
Displacement 2198 cc
Compression ratio 15.6:1
Power output at _3200 rpm 96 kW (130 PS)
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Torque between 1600 to 2500 rpm 320 Nm
Idle speed 800 rpm
Engine Data — 160 PS
Description
Code GBVAJQJ
Bore diameter 86 mm
Stroke 94.6 mm
Power output at _3200 rpm 118 kW (160 PS)
Idle speed 800 rpm
Engine Oil Capacity
Description Liters
Service fill without oil filter 8.2
Cylinder Block Dimensions
Description mm
Cylinder bore diameter 86.000-86.020
Main bearings radial clearance 0.028-0.072
Main bearings 1 to 4 parent bore diameter — vertical measurement 69.504-64.520
Main bearing 5 parent bore diameter — vertical measurement 74.504-74.520
Main bearings 1 to 4 parent bore diameter — horizontal measurement 69.502-69.525
Main bearing 5 parent bore diameter — horizontal measurement 74.502-74.525
Piston Dimensions
Description mm
Piston diameter 85.950-85.934
Piston clearance in cylinder 0.05-0.086
Piston ring end gaps
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— upper compression ring 0.25-0.035
— lower compression ring 0.85-1.1
— oil control ring 0.2-0.4
Piston ring gap position: The piston ring gaps must be distributed evenly around the circumference of the piston. This
also applies to the oil control ring elements. Align the piston ring gaps at 120 degrees to each other.
Crankshaft Dimensions
Description mm
Main bearing journal end float 0.090-0.305
Main bearing journals 1 to 4 diameter 64.950-64.970
Main bearing journal 5 diameter 69.950-69.970
Connecting rod bearing journal diameter 52.980-53.000
Connecting Rod Dimensions
Description mm
Bearing clearance 0.04-0.09
Large end bore diameter 55.996-56.016
Small end bore diameter 30.010-30.018
Connecting rod bearing shell inner diameter — bearings installed 53.017-53.043
Connecting rod bearing radial clearance 0.034-0.100
Connecting rod bearing axial clearance 0.100-0.320
Connecting Rod Grade Selection
Crank Pin to Cylinder Head Face 'X' (mm) Connecting Rod Grade Connecting Rod Length (mm)

176.255-176.319 A 154.905-154.964 (154.94)
176.320-176.365 B 154.965-155.035 (155.00)
176.366-176.369 A 154.905-154.964 (154.94)
176.370-176.440 B 154.965-155.035 (155.00)
176.441-176.460 C 155.036-155.095 (155.06)
Piston Pin Dimensions
Description mm
Piston pin length 66.85-66.87
Piston pin diameter 29.995-29.999
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Piston pin slide clearance 0.013-0.022
Camshaft Dimensions
Description mm
Camshaft end float 0.014-0.20
Camshaft bearing journal diameter 26.450
Camshaft bearing clearance — radial measurement 0.065
Valve Dimensions
Description mm
Valve stem to valve guide clearance — intake valve 0.045
Valve stem to valve guide clearance — exhaust valve 0.055
Valve seat width 26
Cylinder Head Dimensions
Description mm
Maximum distortion — measured longitudinally and diagonally over 25mm,over 150 mm,over 0.025,0.050,0.10
distance in excess of 150mm
Peak to valley height of mating surface 0.02
Thickness of cylinder head gasket with piston protrusion of 0.430 - 0.520 mm 0.01
Thickness of cylinder head gasket with piston protrusion of 0.521 - 0.570 mm 1.15(two
hole/teeth)
Thickness of cylinder head gasket with piston protrusion of 0.571 - 0.620 mm 1.2(three
holes/teeth)
Oil Pressure Specifications
Description bar
Minimum oil pressure at idle speed 1.25
Minimum oil pressure at 2000 rpm 2.0
Lubricants, Fluids, Sealers and Adhesives (for markets with low sulphur content less than 350 ppm)
Item Specification
Engine Oil WSS-M2C913-C
Engine Oil WSS-M2C913-D
Sealer — oil pan, camshaft carrier and engine front cover WSE-M4G323-A4
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Lubricants, Fluids, Sealers and Adhesives (for markets with high sulphur content greater than 350 ppm)
Item Specification
Engine Oil WSS-M2C921-A
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Procedure
Description and Operation revision date:
06/5/2015
Engine
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Item Part Number Description

1 — Oil cooler
2 — Oil filter
3 — Fuel pump
4 — Coolant pump
5 — Intake manifold
6 — Fuel injection rail

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1 — Valve cover
2 — Vacuum pump
3 — Exhaust manifold
4 — Turbocharger
5 — Oil pan

1 — VIN (Vehicle identification number)
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Procedure
06/5/2015
Engine - Overview
Duratorq-TDCi
NOTE: The 2.2L and 3.2L Duratorq-TDCi engines are members of the “Global Puma” engine family. The 3.2L engine
shares the design of the 2.2L engine with an extra cylinder added.
The 2.2L Duratorq-TDCi engine is a 4 cylinder common rail, turbo charged diesel engine which delivers a power of 118
kW.
The 3.2L Duratorq TDCi engine is a 5 cylinder common rail, turbo charged diesel engine which delivers a power of
147kW and the maximum torque is 470 Nm.
The engines have a cast iron cylinder block with a ladder frame in order to increase rigidity and reduce vibration.
The engine turbocharger is a variable guide vane type. The guide vanes are electrically adjustable.
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Engine Features
4 or 5-cylinder turbo diesel in-line engine with two overhead camshafts and 16 valve technology
Cast iron cylinder block with cast-in cylinder liners
Ladder frame for extending the cylinder block
Two-part cylinder head made from aluminium
Intake and exhaust camshaft and fuel high pressure pump driven a timing chain
Oil pump drive by chain
Oil level/oil temperature sensor
Camshaft driven vacuum pump
Valves actuated by roller cam followers with hydraulic tappets
Variable-geometry turbocharger for optimum cylinder charging
Fuel System
Continental common rail system 1800 bar
Fuel injectors with piezo technology
Engine Management
Continental PCM
Volume control valve, fuel inlet temperature sensor and fuel rail pressure sensor for efficient regulation of fuel
pressure
Actuator motor-controlled EGR (exhaust gas recirculation) valve
Engine-Emission Control
Depending on region Meets EURO 2,4 or 5
Actuator motor-controlled EGR valve and cooled by water
Electronic throttle body with position sensor
Broadband Lambda probe for correcting the injection volume and for optimizing the EGR
Coated DPF (diesel particulate filter) to minimize particle emissions (region dependent)
Engine Components
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Item Description
1 Valve cover
2 Housing valve rocker arm
3 Cylinder head
4 Cylinder block and ladder frame
5 Oil pan
Cylinder Head
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Cylinder head consists of two parts and is made of aluminum. Both parts are bolted to each other.
Lower part contains four valves for each combustion chamber and the two camshafts.
The upper part houses the rocker arm frame with the roller rocker arms. The hydraulic valve clearance adjustment is
integrated in the roller rocker arms.
Camshafts and the fuel injection pump are driven by the crankshaft via the timing chain.
Oil pump is located inside the oil pan and is driven by the crankshaft via a chain.
NOTE: Cylinder 1 is located on the timing chain end.
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Procedure
05/6/2015
Engine - System Operation and Component Description
System Operation
Continental common rail fuel injection system
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Item Description
1 Electrical connector
2 Fuel return line clip
3 Fuel injector
4 Sealing washer
5 Injector nozzle
6 High pressure fuel supply line union
The continental common rail fuel injection system works in a similar fashion to a petrol fuel injection system where
fuel is supplied to the injector via a fuel rail. The injection control occurs at the injector.
NOTE: Fuel injectors for the 2.2L Duratorq TDCi HP engine have a higher flow rate than for the other two versions.
The piezo injectors, which are hydraulically connected to the fuel rail, inject the necessary amount of fuel into the
combustion chamber for all operating conditions of the engine. The injector is centralized in the combustion chamber.
The injection quantity is composed of a pre-injection amount and a main-injection amount. This separation causes a
"soft" combustion operation of the diesel engine reducing Diesel 'knock'.
Piezo actuators ensure extremely quick response times are possible, and are faster than solenoid injectors. Because
of this, the injected fuel amount and the dosage can be extremely accurately controlled. The injectors are controlled
by the PCM.
The fuel rail is made from forged steel and is retained by a support bracket located on the camshaft carrier. The fuel is
delivered by one high-pressure fuel supply line from the fuel pump to the fuel rail. From the fuel rail, the fuel travels
through high-pressure fuel supply lines to the fuel injectors. At the end of the fuel rail is the fuel pressure sensor.
NOTE: Whenever a high pressure fuel line is removed it must be replaced with a new part.
NOTE: The fuel pressure sensor is never to be removed from the fuel rail. If faulty it must be replaced together with
the fuel rail as an assembly.
Fuel pump
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Item Description
1 Fuel return bleed from injectors
2 Fuel metering valve
3 Fuel temperature sensor
4 Fuel supply from tank
5 High pressure outlet to fuel rail
The high pressure fuel pump is driven via the timing chain, and houses two pumps. A low-pressure vane pump and a
three cylinder positive displacement pump. The cylinders are staggered at 120°. The fuel volume flow is variable.
The low pressure part of the pump supplies the high pressure part with fuel for pressure generation. Between the low
and high pressure parts of the pump the volumetric control valve is fitted to limit the fuel volume flow.
The fuel enters the high pressure part of the pump where high pressure is generated and the fuel is pumped to the fuel
pressure regulator where the pressure is controlled to between 230 bar and 1800 bar. The fuel then leaves the fuel
pump and is supplied to the fuel rail.
The combination of piezo injectors and the ability to rapidly increase and decrease the fuel pressure gives the engine
the ability to vary the amount of fuel being injected in a given time, and for the injector to react very quickly. This
enables a small pre-injection then a larger main injection. Having a pre-injection and a main injection reduces
combustion noise and, emissions while increasing performance and economy. The fuel pressure, injection timing, and
duration are all controlled by the PCM.
Vacuum pump
The diesel engines are fitted with a vacuum pump to provide the brake booster with vacuum in order to assist with
braking. The vacuum pump is mounted on the rear of the cylinder head and is driven via the exhaust camshaft.
Intake manifold flap
Mounted on the intake manifold is a servo controlled flap. The intake manifold flap unit has the following functions:
preventing "serious engine judder" when the engine is stopped
throttling of the intake air during the DPF regeneration process
The intake manifold flap is actuated by a DC motor. Actuation is performed via Pulse Width Modulation (PWM) which
is controlled by the PCM. The position of the intake manifold flap is detected by a position sensor (potentiometer).
The output signal is an analogue voltage signal.
Engine oil quality
Ranger is fitted with a warning light on the instrument cluster. When illuminated, the PCM has calculated the
acceptable level of contaminants and soot in the engine oil has been exceeded. The oil quality calculation strategy is
loaded in the PCM software. This strategy calculates the oil quality taking into consideration various engine operating
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conditions including trip duration, engine speed and load. When the PCM requests an oil change, the warning lamp is
activated. This warning lamp signals to the driver that an oil change must be carried out irrespective of the kilometres
travelled since the last service. After the oil change, the parameters for the oil quality calculation strategy must be
reset.
To reset the oil change warning lamp;
1. Push and hold brake pedal and simultaneously hold the accelerator pedal at full throttle.
2. Turn the ignition to the 'On' position
3. Wait minimum 10 secs.
4. Release both brake and accelerator pedals and turn the key to the 'Off' position.
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Procedure revision
Diagnosis and Testing date: 02/22/2015
Engine
1. For basic mechanical concerns.
REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
For driveability concerns. Refer to Powertrain Control/Emissions Diagnosis (PC/ED) manual.
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Procedure
Removal and Installation revision date:
06/5/2015
Camshafts
100-010
303-1587
Timing Tool, Crankshaft
6 mm Drill Bit
2 mm Punch
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Removal
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow
these instructions may result in personal injury.
1. Refer to: Fuel Rail (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L
Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Removal and Installation).
2. Refer to: Valve Cover (303-01B Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
(96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/2.2L Duratorq-TDCi (118kW/160PS) -
Puma, Removal and Installation).
3. Refer to: Timing Cover (303-01B Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
4. Refer to: Brake Vacuum Pump - RHD (206-07 Power Brake Actuation, Removal and Installation).


7.
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8.

9. NOTICE: Remove the camshaft carrier bolts in the sequence shown.

Installation
NOTE: Clean the mating faces of the camshaft carrier and the cylinder head.
Bolts 1 to 22
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Torque: 23 Nm
Bolts 23 to 25
Torque: 10 Nm

2. Ensure rockers are seating on the valve tip prior to commencing rundown.
Torque:
Stage 1: 5 Nm
Stage 2: 8 Nm
Stage 3: 10 Nm
Stage 4: 45°

3.
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4. Install Special Service Tool: 303-1587 Timing Tool, Crankshaft.

5. NOTE: Make sure that the installation marks are aligned.
Use the General Equipment: 6 mm Drill Bit
Torque: 33 Nm

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6. Remove the 6 mm drill bits.
1. Torque: 14 Nm
2. Torque: 31 Nm
3. Torque: 15 Nm


9. Remove Special Service Tool: 303-1587 Timing Tool, Crankshaft.
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10. Rotate the engine two revolutions.

12. Check the valve timing by inserting the drill bits. If the drill bits cannot be inserted repeat the timing steps.

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15. Refer to: Brake Vacuum Pump - RHD (206-07 Power Brake Actuation, Removal and Installation).
16. Refer to: Timing Cover (303-01B Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
18. Refer to: Fuel Rail (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L
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Procedure revision
Removal and Installation date: 03/22/2011
Crankshaft Front Seal
303-1310
Holding Wrench, Crankshaft
303-679A
Remover/Installer, Engine Front Cover Inspection Plate
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Removal
1.
1. Do not completely loosen the crankshaft pulley bolts.
Use Special Service Tool: 303-1310 Holding Wrench, Crankshaft.

3. Use Special Service Tool: 303-679A Remover/Installer, Engine Front Cover Inspection Plate.

Installation
1. NOTE: Make sure that mounting face is clean and lubricated.
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2. NOTICE: A new crankshaft seal carrier is supplied with an alignment sleeve that must not be removed
until the crankshaft seal if fully installed. Failure to follow this instruction may result in damage to the
crankshaft.

3.
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4. NOTE: Initially hand tighten the fastners.
Torque:
Stage 1: 45 Nm
Stage 2: 120°

5.
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Procedure revision
303-254
Materials
Name Specification
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Removal
Vehicles with automatic transmission
1. Refer to: Transmission - 4x2 (307-01 Automatic Transmission - 6-Speed Automatic Transmission - 6R80,
Removal).
Refer to: Transmission - 4x4 (307-01 Automatic Transmission - 6-Speed Automatic Transmission - 6R80,
Removal).
Vehicles with manual transmission
and Installation).
Refer to: Clutch Disc and Pressure Plate (308-01B Clutch - 6-Speed Manual Transmission - MT82, Removal
and Installation).
All vehicles

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4.

Installation
All vehicles
1.

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2. NOTE: Install new crankshaft rear seal carrier with in five minutes after applying the recomended sealent.

3. NOTICE: A new crankshaft rear seal carrier is supplied with an alignment sleeve that must not be
removed until the crankshaft rear seal is fully installed. Failure to follow this instruction may result in
damage to the vehicle.
Hand tighten the bolts at this stage.

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4. NOTE: New crankshaft seal carriers are supplied with an alignment sleeve which must be removed after
installation.
Torque: 10 Nm

5. NOTE: Make sure that flywheel is in full contact with flywheel flange before installing the flywheel bolts.

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6. Torque:
Stage 1: 15 Nm
Stage 2: 30 Nm
Stage 3: 75 Nm
Stage 4: 45°

and Installation).
Refer to: Clutch Disc and Pressure Plate (308-01B Clutch - 6-Speed Manual Transmission - MT82, Removal
and Installation).
Installation).
Installation).
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Procedure revision
Cylinder Head
205-069
Dial Indicator Gauge (Metric)
205-070
Holding Fixture, Dial Indicator Gauge
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303-432
Holding Fixture, Dial Indicator Gauge (Cylinder Liner Protrusion)
Removal
1. Refer to: Intake Manifold - Emission Requirements: EURO Stage V LDT (303-01B Engine - 2.2L Duratorq-
TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) -
Puma/2.2L Duratorq-TDCi (118kW/160PS) - Puma, Removal and Installation).
2.

3. Torque:
1: 8 Nm
2: 13 Nm

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4. Refer to: Exhaust Gas Recirculation (EGR) Valve - 2.2L Duratorq-TDCi (118kW/160PS) - Puma (303-08B
Engine Emission Control - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) -
Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/2.2L Duratorq-TDCi (118kW/160PS) - Puma, Removal and
Installation).
5. Refer to: Exhaust Manifold (303-01B Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
6. Refer to: Camshafts (303-01B Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
7.

Installation
1. WARNING: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means
to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a
plastic scraping tool to remove all traces of the head gasket.

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2. NOTE: Measure the piston protrusion of each cylinder at top dead center (TDC)
Measure the distance between the piston crown and the cylinder block at the points indicated.

3. NOTE: The largest measurement determines the choice of the cylinder head gasket.
Use Special Service Tool: 303-432 Holding Fixture, Dial Indicator Gauge (Cylinder Liner Protrusion). , 205-070
Holding Fixture, Dial Indicator Gauge. , 205-069 Dial Indicator Gauge (Metric).

4. NOTE: Make sure that new component is installed.
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5.

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6. NOTICE: Make sure that new cylinder head bolts are installed.
NOTE: Install all the bolts finger tight before final tightening.
Torque:
Stage 1: 1 -10: 10 Nm
Stage 2: 11-18: 5 Nm
Stage 3: 1-10: 20 Nm
Stage 4: 11-18: 10 Nm
Stage 5: 1-10: 35 Nm
Stage 6: 11-18: 20 Nm
Stage 7: 1-10: 45 Nm
Stage 8: 11-18: 26 Nm
Stage 9: 1-10: 90°
Stage 10: 11-18: 90°
Stage 11: 1-10: 90°
Stage 12: 11-18: 90°
Stage 13: 19: 4 Nm
Stage 14: 19: 6 Nm
Stage 15: 19: 10 Nm

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Procedure revision
Exhaust Manifold
Removal
1.
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2. Refer to: Turbocharger - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) -
Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma (303-04D Fuel Charging and Controls - Turbocharger - 2.2L
Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi
(110kW/150PS) - Puma/2.2L Duratorq-TDCi (118kW/160PS) - Puma, Removal and Installation).
Refer to: Generator - 2.2L Duratorq-TDCi (Puma) Diesel (414-02 Generator and Regulator, Removal and
Installation).
Refer to: Turbocharger - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) -
Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Emission Requirements: EURO Stage V LDT (303-04D
Fuel Charging and Controls - Turbocharger - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
1. Torque: 25 Nm
2. Torque: 23 Nm
3. Torque: 9 Nm

1. Torque: 55 Nm
2. Torque: 40 Nm
3. Torque: 15 Nm
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5.

Installation
NOTE: Install new exhaust manifold studs, bolts, nuts, gaskets and O-ring seals.
1. To install , reverse the removal procedure.
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Procedure
07/6/2015
Intake Manifold - Emission Requirements: EURO Stage V LDT
Removal
WARNING: Do not carry out any repairs to the fuel injection system with the engine running. The fuel
pressure within the system is approximately 1600 bars. Failure to follow this instruction may result in
personal injury.
WARNING: Wait at least one minute after the engine stops before commencing any repair to the fuel
injection system. Failure to follow this instruction may result in personal injury.
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1.

2. Torque: 3 Nm

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4.

5. Torque: 11 Nm

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Installation).
7.

2. Torque: 10 Nm
3. Torque: 10 Nm

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9.

10.

Installation
1. Torque:
Stage 1: 5 Nm
Stage 2: 13 Nm
Stage 3: 16 Nm

2. NOTE: Inspect the intake manifold gaskets, Install new intake manifold gaskets if necessary.
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To install, reverse the removal procedure.
Procedure
06/5/2015
Timing Cover
303-428
Separator, Oil Pan
303-682
Aligner, Engine Front Cover
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Materials
Name Specification

Removal
2. Refer to: Cooling Fan (303-03B Engine Cooling - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-
TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/2.2L Duratorq-TDCi (118kW/160PS)
- Puma, Removal and Installation).
3. Refer to: Generator - 2.2L Duratorq-TDCi (Puma) Diesel (414-02 Generator and Regulator, Removal and
Installation).
4. Torque: 23 Nm

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1. Torque: 48 Nm
2. Torque: 23 Nm

6. Torque: 48 Nm

Refer to: Engine Undershield (501-02 Front End Body Panels, Removal and Installation).
8. Torque: 30 Nm

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9. Refer to: Crankshaft Front Seal (303-01B Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-

Installation
NOTE: To remove oil from the cylinder block flange bonderite 1455-w wipes must be used.
NOTE: Loctite 7070 or other de-contaminator must not be used on cylinder block flanges.
NOTE: Always apply bonderite 1455 wipes to (4) x t-joints(block/head, block/ladderframe).
NOTE: Apply bonderite 1455-w wipes to (2) x t-joints(head/cam-carrier interfaces).
NOTE: One minute flash time is recommended after bonderite 1455-w application. apply different section of wipes to
each t-joints and do not re-use.
1. NOTICE: Install timing cover with in five minutes of applying the sealent.
NOTE: Do not damage the mating surfaces.
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2. Use Special Service Tool: 303-682 Aligner, Engine Front Cover.
Torque:
Stage 1: 5 Nm
Stage 2: 10 Nm
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Procedure revision
Oil Pan - 4x2
303-428
Separator, Oil Pan
Plastic Scraper
Materials
Name Specification
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Removal
3. Refer to: Steering Gear - RHD 4WD (211-02B Power Steering - Vehicles With: Electronic Power Assist
Steering (EPAS), Removal and Installation).
Refer to: Steering Gear - LHD 4WD (211-02B Power Steering - Vehicles With: Electronic Power Assist
4. Refer to: Steering Gear - RHD 4WD/RHD RWD/RHD (211-02A Power Steering, Removal and Installation).
Refer to: Steering Gear - LHD 4WD/LHD RWD (211-02A Power Steering, Removal and Installation).
All vehicles
Drain the oil pan into a suitable container.
Torque: 39 Nm

7.
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Installation
1. NOTE: Do not damage the mating faces.
Use Special Service Tool: 303-428 Separator, Oil Pan.

Use the General Equipment: Plastic Scraper
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Install the oil pan within five minutes of applying the sealer.

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4. Torque:
Stage 1: 7 Nm
Stage 2: 14 Nm

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Procedure revision
Oil Pan - 4WD
303-290-01
303-290-03A
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303-290B
Support Bar, Engine
303-428
Separator, Oil Pan
Plastic Scraper
Transmission Jack
Interior Trim Remover
Materials
Name Specification

Silicone Sealant WSS-M4G323-A8

Removal
All vehicles
Torque: 39 Nm

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9.

10. On both sides.

12. Use the General Equipment: Interior Trim Remover
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13. Refer to: Cooling Fan (303-03B Engine Cooling - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-
Use Special Service Tool: 303-290-01 Adapter for 303-290A. , 303-290B Support Bar, Engine. , 303-290-03A

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16.

17. WARNING: Always secure engines, transmissions, or other heavy components to the support
fixture with straps and wooden support blocks. Improperly secured assemblies could fall off the fixture,
resulting in serious personal injury.

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18.

Installation

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4. Torque:
Stage 1: 7 Nm
Stage 2: 14 Nm

5. Torque: 25 Nm

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NOTE: Make sure that new nuts are installed.
NOTE: Make sure that new bolts are installed.
Remove the transmission jack.
Torque:
1.: 90 Nm
2.: 265 Nm
3.: 110 Nm

8. Remove the special tools.

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9.

10. Raise the Vehicle.
11. On both sides.
Torque: 175 Nm

Install the Front axle tube within five minutes of applying the sealer.
Material: Silicone Sealant (WSS-M4G323-A8)
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1. Torque: 70 Nm
2. Torque: 40 Nm

All vehicles
Refer to: Specifications (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Specifications).
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Procedure revision
Oil Pan - Base
303-290-01
303-290-03A
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303-290B
Support Bar, Engine
303-428
Separator, Oil Pan
Plastic Scraper
Materials
Name Specification

Removal
1. Refer to: Battery Disconnect and Connect - Vehicles Built Up To: 16-08-2015 (414-01 Battery, Mounting and
Cables) .
2. Refer to: Jacking - Vehicles Built Up To: 16-08-2015 (100-02 Jacking and Lifting) .
Refer to: Lifting - Vehicles Built Up To: 16-08-2015 (100-02 Jacking and Lifting) .
4.

Torque: 39 Nm
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6.

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7.

8. NOTICE: Take extra care when handling steering gear rack.

4X4
9. Remove the front wheel.
10. Refer to: Differential Draining and Filling - Vehicles Built Up To: 16-08-2015 (205-03 Front Drive
Axle/Differential) .
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12.

13. On both sides.


16. Refer to: Cooling Fan (303-03C Engine Cooling - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and
Installation).
Refer to: Cooling Fan (303-03B Engine Cooling - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-
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19.

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All vehicles

21.

Installation
All vehicles
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4. Torque:
Stage 1: 7 Nm
Stage 2: 14 Nm

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4X4
5. Torque: 25 Nm


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8.

10. On both sides.
Torque: 175 Nm

11. NOTICE: Install the Front axle tube within five minutes of applying the sealer.
Material: WSS-M4G323-A8
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1. Torque: 70 Nm
2. Torque: 40 Nm

14. Install the front wheel.
All vehicles
16. Torque: 150 Nm

17. Torque: 90 Nm
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18. Torque: 90 Nm

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19. Torque: 90 Nm

Refer to: Specifications - Vehicles Built Up To: 16-08-2015 (303-01 Engine - 2.2L Duratorq-TDCi (88kW/120PS)
- Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/2.2L Duratorq-
TDCi (118kW/160PS) - Puma) .
22. Refer to: Battery Disconnect and Connect - Vehicles Built Up To: 16-08-2015 (414-01 Battery, Mounting and
Cables) .
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Procedure
06/3/2016
Oil Pump
303-705
Aligner, Oil Pump
Materials
Name Specification
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Removal
2. Refer to: Oil Pan - 4WD (303-01B Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
Refer to: Oil Pan - 4x2 (303-01B Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
3.


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1. NOTE: Make sure that the surface is clean and free of foreign material.
2. Use Special Service Tool: 303-705 Aligner, Oil Pump.
3. Torque: 15 Nm

6. NOTE: Do not completely loosen the bolts at this stage.
Remove Special Service Tool: 303-705 Aligner, Oil Pump.

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7.

Installation
1. NOTE: Only tighten the bolts finger tight at this stage.
NOTE: Make sure that the installation marks are aligned.
Use Special Service Tool: 303-705 Aligner, Oil Pump.

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2. NOTE: The profile of the special tool must be in contact with the component.
Torque: 10 Nm

3. NOTE: Lubricate the "O" ring before installing.
Make sure that a new component is installed if the O-ring is damaged.
Inspect the O-ring before installation.

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4. Torque: 10 Nm

Make sure that a new component is installed if the O-ring is damaged.

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6. Torque: 13 Nm

Refer to: Oil Pan - 4x2 (303-01B Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
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Procedure revision
Valves
303-060
303-060-05
Adapter for 303-060
303-060-07
Adapter for 303-060
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303-362
Removal
1. Refer to: Cylinder Head (303-01B Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
2. NOTE: Position a socket on the valve spring seat and gently strike it with a hammer.

3. Use Special Service Tool: 303-060 Compressor, Valve Spring. , 303-060-05 Adapter for 303-060. , 303-060-07
Adapter for 303-060. , 303-362 Installer, Valve Stem Collets.

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4.

Installation
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Procedure revision
Valve Cover
Removal
All vehicles
1.
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Vehicles with fixed vane turbocharger
2.

1. Torque: 10 Nm
2. Torque: 23 Nm

All vehicles
4. Refer to: Fuel Injectors (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L
1. Torque:
Stage 1: 5 Nm
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Stage 2: 35 Nm
2. Torque: 10 Nm

6.

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7. Torque: 10 Nm

8.

Installation
NOTE: Install a new valve cover gasket as necessary.
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Procedure revision
Valve Stem Seals
303-037
Installer, Valve Stem Seal
303-508
Removal
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1. Refer to: Valve Springs (303-01B Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi

Installation
1. Use Special Service Tool: 303-037 Installer, Valve Stem Seal.

2. Refer to: Valve Springs (303-01B Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
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Procedure
06/5/2015
Valve Springs
303-060
303-060-05
Adapter for 303-060
303-060-07
Adapter for 303-060
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303-362
Removal
2.

3. Position the appropriate piston at top dead center (TDC).
4. Using the special tools, remove the valve collets.
Use Special Service Tool: 303-060 Compressor, Valve Spring. , 303-060-05 Adapter for 303-060. , 303-060-07

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Installation
1.

2. Ensure rockers are seating on the valve tip prior to commencing rundown.
Torque:
Stage 1: 5 Nm
Stage 2: 8 Nm
Stage 3: 10 Nm
Stage 4: 45°

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Procedure
Removal revision date:
05/6/2015
303-122
Transmission Jack
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3. Refer to: Cooling System Draining, Filling and Bleeding (303-03B Engine Cooling - 2.2L Duratorq-TDCi
Puma/2.2L Duratorq-TDCi (118kW/160PS) - Puma, General Procedures).
6.

7.

10.
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11.

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12. Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
13. Refer to: Powertrain Control Module (PCM) (303-14A Electronic Engine Controls - 2.5L Duratec-HE
(122kW/165PS) - MI4, Removal and Installation).
Refer to: Powertrain Control Module (PCM) (303-14B Electronic Engine Controls - 2.2L Duratorq-TDCi
14.

15.

16.
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17.

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18. Refer to: Radiator (303-03B Engine Cooling - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
19. Refer to: Condenser - 3.2L Duratorq-TDCi (Puma) Diesel (412-00 Climate Control System - General
Information, Removal and Installation).
20.

21. Refer to: Starter Motor (303-06B Starting System - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-
TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Removal and Installation).
22.

23.
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24. Refer to: Air Cleaner - 2.2L Duratorq-TDCi (Puma) Diesel (303-12B Intake Air Distribution and Filtering - 2.2L
25. NOTE: Make sure that all openings are sealed.

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26. NOTICE: Cap the power steering line to prevent fluid loss or dirt ingress.
NOTE: The washers can be reused unless damaged.

All vehicles
27.

28.
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29.

30. Refer to: Catalytic Converter (309-00B Exhaust System - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L
(118kW/160PS) - Puma, Removal and Installation).
31.

32.
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33.

34.
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35.

retaining straps.
NOTICE: Do not tilt the transmission.This may cause damage to the pilot bearing.
Tie and support the transmission to the chassie with a suitable strap.

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37.

38.

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39. On both sides.


41.

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42.

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Procedure revision
Removal date: 05/19/2015
303-122
Transmission Jack
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6.

7.

8.
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11.

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12.

14. Refer to: Powertrain Control Module (PCM) (303-14B Electronic Engine Controls - 2.2L Duratorq-TDCi
15.

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16.

17.

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18.

21.

23.
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24.


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All vehicles
28.

29.
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30.

31. Refer to: Catalytic Converter - Emission Requirements: EURO Stage V LDT (309-00B Exhaust System - 2.2L

32.

33.
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34.

35.
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36.

retaining straps.
NOTICE: Do not tilt the transmission.This may cause damage to the pilot bearing.
Tie and support the transmission to the chassie with a suitable strap.

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38.

39.

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40. On both sides.


42.

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43.

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Procedure
05/6/2015
Engine - 6-Speed Automatic Transmission - 6R80
303-122
307-346 (T97T-7902-A)
Retainer, Torque Converter
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Transmission Jack
6.

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7.

8.

11.

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12.

15.

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16.

17.

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18.

21.

23. Refer to: Transmission Fluid Cooler (307-02 Transmission Cooling, Removal and Installation).
24.
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25.


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All vehicles
29.

30.
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31.

33.

34.
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35.

36.
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37.

retaining straps.
Tie and support the transmission to the chassis with a suitable strap.

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39.

40.

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41.

42.

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43. On both sides.


45.

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46. Install Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.

47.

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Procedure
05/6/2015
Engine Accessories
303-122
303-1310
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303-1317
Locking Tool, Fuel Injection Pump Sprocket
303-249-01
Adapter for 303-249
303-254
303-435
Mounting Stand
303-435-06
303-435-11B
303-679A
Dowel with a Diameter of 6 mm
1/2 Inch Square Drive Breaker Bar
1. Install Special Service Tool: 303-122 Lifting Bracket, Engine.

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2.

3.

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4.

5.

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6.

7. Install Special Service Tool: 303-435-11B Mounting Plate for 303-435-06.

8. Install Special Service Tool: 303-435 Mounting Stand. , 303-435-06 Mounting Bracket for 303-435.
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9. Remove Special Service Tool: 303-122 Lifting Bracket, Engine.

10. Use the General Equipment: 1/2 Inch Square Drive Breaker Bar
Use the General Equipment: Dowel with a Diameter of 6 mm

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11.

2. NOTE: Rotate the accessory drive belt tensioner clockwise.
3. Use the General Equipment: Dowel with a Diameter of 6 mm

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All vehicles

14.

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15.

16.

17.

NOTE: The studs are to be reused unless damaged.
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19.

20.

21.
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22.

23.

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24. NOTICE: Make sure that all openings are sealed. Use new blanking caps.

25.

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26.

27.

28.
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29.

30. NOTE: Do not loosen the bolts more than 2 turns.

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32.

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33.

34.

35. NOTICE: Make sure that the fuel line remains in contact at both ends until both unions nuts have been
unscrewed and the area around the joints thoroughly cleaned.
NOTICE: Make sure that the high-pressure fuel supply line remains in contact with both the fuel pump
and the fuel rail until both unions have been detached and cleaned.
NOTICE: Make sure that all openings are sealed. Use new blanking caps.

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36.

37.

38.
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39.

40.

41.
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43. NOTE: The component has a left-hand thread.

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44. Install Special Service Tool: 303-1317 Locking Tool, Fuel Injection Pump Sprocket.

45.

46.

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47. Use Special Service Tool: 303-1317 Locking Tool, Fuel Injection Pump Sprocket. , 303-249-01 Adapter for
303-249.

48.

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49.

50.

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51.

52.

53.
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54. Use Special Service Tool: 303-1310 Holding Wrench, Crankshaft.


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Procedure
Disassembly revision date:
07/1/2014
Engine
100-010
303-1317
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303-249-01
Adapter for 303-249
303-428
Separator, Oil Pan
303-679A
2 mm Punch
1. Remove Special Service Tool: 303-1317 Locking Tool, Fuel Injection Pump Sprocket. , 303-249-01 Adapter for
303-249.

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2.

3.

Torque: 55 Nm
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5. Remove Special Service Tool: 303-1317 Locking Tool, Fuel Injection Pump Sprocket.

6. Remove Special Service Tool: 303-679A Remover/Installer, Engine Front Cover Inspection Plate.

7.
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9.

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11. Remove and discard the timing chain tensioner.

12.

13.
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14.

15.

16.
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17.

18.

19. WARNING: Be prepared to collect escaping fluid.
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21.

22.

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23.

24.

25.
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26.

27.

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30.

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Procedure
Disassembly and Assembly of Subassemblies revision date:
05/4/2011
Cylinder Head
Disassembly
1.
For additional information, refer to: Valves (303-01B Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L
2. Torque : 13 Nm
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3. Torque : 23 Nm

Assembly
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Procedure revision
Disassembly and Assembly of Subassemblies date: 08/19/2015
Piston
Materials
Name Specification

DISASSEMBLY
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.
1. Remove and discard the piston rings.
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2. Remove and discard the piston pin retainers. Remove the piston pin.

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3. Separate the piston from the connecting rod. Clean and inspect the piston.

ASSEMBLY
1. NOTE: Align the piston-to-connnecting rod orientation marks made during disassembly.
Align the front of the piston and connecting rod. Assembly the piston and the connecting rod.
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2. Lubricate with clean engine oil and install the piston pin.

3. Install the piston pin retainers.

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4. NOTE: The rings are to be fitted with the paint mark to the left of the piston ring gap.
NOTE: The upper and lower compression ring gaps are the be installed 180 degrees apart.
NOTE: The oil control ring position is not controlled.
Lubricate with clean engine oil and install the piston rings.

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Procedure
Assembly revision date:
07/1/2015
Engine
205-044
205-069
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205-070
303-1562
Timing Tool
303-1587
303-254
303-428
Separator, Oil Pan
303-432
303-682
303-698
6 mm Drill Bit
Piston Ring Compressor
Materials
Name Specification

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1. NOTE: Make sure that these components are installed to the noted removal position.
Torque: 10 Nm


Torque:
Stage 1: 6 Nm
Stage 2: 15 Nm
Stage 3: 20 Nm
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Stage 4: 35 Nm
Stage 5: 80 Nm
Stage 6: 90°

4. Use the General Equipment: Piston Ring Compressor

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Torque:
Stage 1: 4 Nm
Stage 2: 25 Nm
Stage 3: 37 Nm
Stage 4: 90°

7.
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9. Using a straight edge, align the rear surface of the ladderframe with the rear surface of the engine block. The
rear clearance does not exceed 0.05 mm gap.
Use Special Service Tool: 303-432 Holding Fixture, Dial Indicator Gauge (Cylinder Liner Protrusion).

10. Using a straight edge, align the side surface of the ladderframe with the side surface of the engine block. The
side clearance does not exceed 0.01mm overlap.
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11. Torque: 23 Nm


13. Take a reference measurement from the front face of the crankshaft sprocket.
Use Special Service Tool: 205-044 Holding Fixture, Dial Indicator Gauge. , 205-069 Dial Indicator Gauge
(Metric).
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14. Take measurements at two different points on the oil pump sprocket and align the oil pump sprocket.
(Metric).

15. Torque: 10 Nm

16.
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17. NOTE: A new crankshaft rear seal carrier is supplied with an alignment sleeve that must not be removed until
the crankshaft rear seal is fully installed. Failure to follow this instruction may result in damage to the vehicle.
Clean the area on the engine before installing a new crankshaft rear seal carrier.
Check the two foam pads are located as shown on the ladder frame gasket.

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18.

Failure to follow this instruction may result in damage to the vehicle.
NOTE: Do not add any more than the specified quantity of sealant or add the sealant anywhere other than the
area shown.
NOTE: If the foam pads are not present on inspection, fill the square areas shown with 75% of sealant.

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NOTE: Initially hand tighten the fasteners.

installation.
Torque:
:
Stage 1: 5 Nm
Stage 2: 10 Nm

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22. NOTE: Make sure that flywheel is in full contact with flywheel flange before installing the flywheel bolts.
NOTE: Only tighten the bolts finger tight at this stage.

23. NOTICE: Make sure that the flywheel is in full contact with the crankshaft flange before installing the
flywheel bolts.
Use Special Service Tool: 303-254 Locking Tool, Flywheel.
Torque:
Stage 1: 25 Nm
Stage 2: 45 Nm
Stage 3: 45°

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24.

25. Initially hand tighten the fasteners.

26. NOTE: Make sure that the special tool is located in the flywheel timing slot.
Use Special Service Tool: 303-698 Timing Tool, Crankshaft.

27. Tighten bolts before removing tool.
Remove Special Service Tool: 303-698 Timing Tool, Crankshaft.
Torque: 20 Nm
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28. Torque: 8 Nm


30. NOTE: Make sure that the special tool is located in the flexplate timing slot.
Use Special Service Tool: 303-1562 Timing Tool.
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Remove Special Service Tool: 303-1562 Timing Tool.
Torque: 20 Nm

32. Torque: 8 Nm

All vehicles
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34. NOTE: Measure the piston protrusion of each cylinder at top dead center (TDC).

Using the special tools, measure the piston protrusion.
Use Special Service Tool: 205-070 Holding Fixture, Dial Indicator Gauge. , 205-069 Dial Indicator
Gauge (Metric). , 303-432 Holding Fixture, Dial Indicator Gauge (Cylinder Liner Protrusion).
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36. Determine the cylinder head gasket.
Refer to: Specifications (303-01B Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
Puma, Specifications).

38.

39. NOTE: Install all the bolts finger tight before final tightening.
Torque:
Stage 1: 1-10: 10 Nm
Stage 2: 11-18: 5 Nm
Stage 3: 19: 4 Nm
Stage 4: 1-10: 20 Nm
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Stage 5: 11-18: 10 Nm
Stage 6: 19: 6 Nm
Stage 7: 1-10: 35 Nm
Stage 8: 11-18: 20 Nm
Stage 9: 19: 10 Nm
Stage 10: 1-10: 45 Nm
Stage 11: 11-18: 26 Nm
Stage 12: 1-10: 90°
Stage 13: 11-18: 90°
Stage 14: 1-10: 90°
Stage 15: 11-18: 90°

40. Material: Silicone Sealant (WSE-M4G323-A4)

41. Torque:
Bolts 1 to 22:
Stage 1: 6 Nm
Stage 2: 15 Nm
Stage 3: 23 Nm
Bolts 23 to 24:
Stage 4: 4 Nm
Stage 5: 5 Nm
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Stage 6: 10 Nm

42. Torque:
Stage 1: 5 Nm
Stage 2: 8 Nm
Stage 3: 10 Nm
Stage 4: 45°

43.
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44. Torque: 23 Nm

45. Torque: 23 Nm

46. Torque: 45 Nm
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47.


Torque:
stage 1: 12 Nm
stage 2: 33 Nm
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1. Torque: 14 Nm
2. Torque: 31 Nm
3. Torque: 15 Nm

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Torque: 15 Nm



56. Check the position of the timing marks and correct if necessary.
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59.
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60. Torque: 10 Nm


62. NOTE: The component must be installed within 5 minutes of applying the sealant.
NOTE: Make sure that a new component is installed.
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Torque:
1: 5 Nm
2: 10 Nm

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66. NOTE: The seal is to be reused unless damaged.
Torque:
Fastners:
Stage 1: 6 Nm
Stage 2: 13 Nm
Seal: 35 Nm
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Procedure revision
Installation date: 05/19/2015
303-122
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3. NOTE: Hand tighten the nut at this stage.

4.

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Torque: 48 Nm

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Torque: 48 Nm

9. Torque: 80 Nm

1. Torque: 48 Nm
2. Torque: 48 Nm
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11. Torque: 80 Nm


13. Torque: 13 Nm
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14.

15. Torque: 22 Nm

16.
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17. Torque:
1: 5 Nm
2: 10 Nm

1. Torque: 47 Nm
2. Torque: 22 Nm

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20. NOTE: The washers can be reused unless damaged.
3. Torque: 35 Nm

21.

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All vehicles
22.

23.

24. Torque: 22 Nm
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26.

30.

31.
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32. Torque: 10 Nm

33. Torque: 18 Nm

34. Torque: 5 Nm
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35.

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36.

41. Torque: 3 Nm

42.
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44. Torque: 30 Nm

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Procedure revision
303-122
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4.

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Torque: 48 Nm

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Torque: 48 Nm

9. Torque: 80 Nm

1. Torque: 48 Nm
2. Torque: 48 Nm
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11. Torque: 80 Nm


13. Torque: 13 Nm
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14.

15. Torque: 22 Nm

16.
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17. Torque:
1: 5 Nm
2: 10 Nm

1. Torque: 47 Nm
2. Torque: 22 Nm

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3. Torque: 35 Nm

21.

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All vehicles
22.

23.

24. Torque: 22 Nm
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25. Refer to: Starter Motor - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) -
Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma (303-06 Starting System - 2.2L Duratorq-TDCi
Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma) .
26.

28. Refer to: Radiator (303-03 Engine Cooling - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
(96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma) .
29. Refer to: Air Cleaner - 2.2L Duratorq-TDCi (Puma) Diesel (303-12 Intake Air Distribution and Filtering - 2.2L
30.

31.
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32. Torque: 10 Nm

33. Torque: 18 Nm

34. Torque: 5 Nm
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35.

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36.

37. Refer to: Powertrain Control Module (PCM) (303-14 Electronic Engine Controls - 2.2L Duratorq-TDCi
38. Refer to: Battery Tray (414-01 Battery, Mounting and Cables) .
41. Torque: 3 Nm

42.
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44. Torque: 30 Nm

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46. Refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling - 2.2L Duratorq-TDCi
Puma) .
Procedure revision
303-122
307-346 (T97T-7902-A)
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Materials
Name Specification
Grease - Electrical Contact WSB-M1C239-A


3. NOTE: Only tighten the nut and bolts finger tight at this stage.

4. NOTICE: Prior to installation of the engine, the torque converter pilot hub must be lubricated with
multipurpose grease or damage to the torque converter or the engine crankshaft can occur.
Lubricate the torque converter pilot hub with multipurpose grease.
Material: Grease - Electrical Contact (WSB-M1C239-A)
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5. Remove Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.

6. NOTE: Make sure that the torque converter remains in the transmission.

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2. NOTE: Make sure that the transmission is installed straight in relation to the engine to prevent damage
to the pilot bearing.

1. NOTE: Make sure that the component is correctly located on the locating dowels.
2. Only tighten the nut finger tight at this stage.
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9. NOTE: Only tighten the nut finger tight at this stage.


Torque: 48 Nm
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Torque: 48 Nm

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13. Torque: 80 Nm

1. Torque: 48 Nm
2. Torque: 48 Nm

15. Torque: 80 Nm

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17. Torque: 13 Nm

18. Torque: 40 Nm

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19. Torque: 22 Nm

20.

21. Torque: 22 Nm
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22.

23. Torque:
1: 5 Nm
2: 10 Nm

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1. Torque: 47 Nm
2. Torque: 22 Nm

26.

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27.

3. Torque: 35 Nm

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29.

All vehicles
30. Torque: 22 Nm

32.
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36.

37.
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38. Torque: 10 Nm

39. Torque: 18 Nm

40. Torque: 5 Nm
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41.

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42.

47. Torque: 3 Nm

48.
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50. Torque: 30 Nm

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Procedure revision
Engine Accessories
303-122
303-1310
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303-1317
303-1562
Timing Tool
303-254
303-435
Mounting Stand
303-435-06
303-435-11B
303-679A
303-698
308-204
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Materials
Name Specification

1.

2. NOTE: Install the new crankshaft rear seal carrier within five minutes of applying the recommended sealant.
area shown.

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Initially hand tighten the fasteners.

installation.
Torque:
Stage 1: 5 Nm
Stage 2: 10 Nm

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5. NOTE: Make sure that the flywheel is in full contact with the crankshaft flange before installing the flywheel
bolts.

Torque:
Stage 1: 25 Nm
Stage 2: 45 Nm
Stage 3: 45°

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9. NOTICE: Tighten the clutch pressure plate retaining bolts by two turns at a time in the sequence shown.
Torque:
Stage 1: 6 Nm
Stage 2: 25 Nm
Stage 3: 30 Nm


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Torque: 25 Nm
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Torque: 8 Nm

6-Speed Automatic Transmission - 6R80

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Torque: 20 Nm

Torque: 8 Nm

All vehicles
19.
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20. Torque: 23 Nm

21. Torque: 23 Nm

Torque: 55 Nm
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25. Torque: 10 Nm

26. Torque: 23 Nm

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27. Torque: 23 Nm

1. Torque: 23 Nm
2. Torque: 23 Nm

29. Torque: 48 Nm
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30. NOTE: Make sure that the mounting face is clean and lubricated.

31. NOTICE: Rotate the seal assembly until it locks. Failure to follow this instruction may result in damage
to the seal assembly.
NOTE: A new crankshaft front seal carrier is supplied with an alignment sleeve that must not be removed until
the crankshaft rear seal is fully installed.
Use Special Service Tool: 303-679A Remover/Installer, Engine Front Cover Inspection Plate.

32. Remove the alignment sleeve after the seal is fully installed.
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33. NOTICE: Crankshaft pulley retaining bolts must only be used three times.
Torque:
Stage 1: 20 Nm
Stage 2: 45 Nm
Stage 3: 90 Nm
Stage 4: 45°

34. Torque: 9 Nm
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1. Torque: 13 Nm
2. Torque: 3 Nm

36. Torque:
Stage 1: 5 Nm
Stage 2: 13 Nm
Stage 3: 16 Nm

37. Record the new fuel injector correction factor code.
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38. NOTE: Using a socket (or similar), press the new fuel injector copper seals onto the fuel injectors making sure
that the copper seals are pushed fully home to prevent uneven clamping.

Torque:
Stage 1: 6 Nm
Stage 2: 360°

40. Torque: 23 Nm
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41. Torque: 23 Nm

NOTE: Vacuum foreign material from the high-pressure fuel supply line, the fuel pump and the fuel rail.
1. Torque:
Stage 1: 15 Nm
Stage 2: 30 Nm
2. Refer to: Fuel Injection Component Cleaning (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi
Puma, General Procedures).
Torque: 10 Nm

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43. Torque:
Stage 1: 15 Nm
Stage 2: 30 Nm

44.

45. NOTICE: Align the camshaft and vacuum pump couplings correctly or damage to the camshaft or
vacuum pump may occur.
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1. NOTE: Before fitting bolts, check that the vacuum pump couple drive and camshaft keyway are aligned.
If a gap is present between vacuum pump and cylinder head, do not fit and run bolts.
NOTE: Under no circumstances should the retaining bolts be tightened if a gap between pump and head
faces is present.

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47. Torque: 23 Nm

48. Torque:
Stage 1: 5 Nm
Stage 2: 10 Nm

49.

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50. Torque: 25 Nm


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2. Torque: 10 Nm
3. Torque: 10 Nm

53.

54.

55.
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56.

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1. Torque:
1:
Stage 1: 10 Nm
Stage 2: 20 Nm
Stage 3: 35 Nm
2:
Stage 4: 10 Nm
Stage 5: 20 Nm
Stage 6: 35 Nm
3: 23 Nm

59. Torque: 9 Nm
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60. Torque: 25 Nm

61. Torque: 23 Nm

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4. Torque: 15 Nm
5. Torque: 48 Nm

63. Torque: 25 Nm

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All vehicles

67. Remove Special Service Tool: 303-435-06 Mounting Bracket for 303-435. , 303-435 Mounting Stand.

68. Remove Special Service Tool: 303-435-11B Mounting Plate for 303-435-06.

69. Torque: 9 Nm
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70. Torque: 23 Nm

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71.

72. Torque:
1: 10 Nm
2: 23 Nm

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1. Torque: 35 Nm
2. Torque: 32 Nm

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303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma 2015 - 2016 Ranger ICA
Specifications Procedure revision date: 02/17/2016
Specifications
Engine Data
Description
Code ENSA
Firing order 1-2-4-5-3
Bore diameter 89.9 mm
Stroke 100.76 mm
Power output at 3000 rpm 143.5 KW (194 PS)
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Idle speed 700 rpm
Maximum oil consumption 0.1L / 1000 Km
Engine Oil Capacity
Description Liters
Service fill without oil filter 9.4
Cylinder Block Dimensions
Description mm
Cylinder bore diameter — Class 1 89.900 - 89.910
Main bearing shells 1 to 5 inner diameter — bearings installed 64.994 - 65.022
Main bearing shell 6 inner diameter — bearings installed 69.994- 70.022
Main bearings 1 to 5 radial clearance 0.028 - 0.072
Main bearing 6 radial clearance 0.028 - 0.072
Main bearings 1 to 5 parent bore diameter — vertical measurement 69.504 - 64.520
Main bearing 6 parent bore diameter — vertical measurement 74.504 - 74.520
Main bearings 1 to 5 parent bore diameter — horizontal measurement 69.502 - 69.525
Main bearing 6 parent bore diameter — horizontal measurement 74.502 - 74.525
Piston Dimensions
Description mm
Piston diameter 89.850 - 89.934
Piston clearance in cylinder 0.05-0.086
Piston ring end gaps
— upper compression ring 0.25-0.35
— lower compression ring 0.50 - 0.75
— oil control ring 0.25 - 0.50
Piston ring gap position: The piston ring end gaps must be distributed evenly around the circumference of the piston.
This also applies to the oil control ring elements. Align the piston ring end gaps at 120 degrees to each other.
Crankshaft Dimensions
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Description mm
Main bearing journal end float 0.090 - 0.305
Main bearing journals 1 to 5 diameter 64.950 - 64.970
Main bearing journal 6 diameter 69.950 - 69.970
Connecting rod bearing journal diameter 52.980 - 53.000
Connecting Rod Dimensions
Description mm
Bearing clearance 0.04-0.09
Large end bore diameter 55.996 - 56.016
Small end bore diameter 32.010 - 32.018
Connecting rod bearing shell inner diameter — bearings installed 53.016 - 53.046
Connecting rod bearing radial clearance 0.026 - 0.084
Connecting rod bearing axial clearance 0.100 - 0.320
Connecting Rod Grade Selection
Crank Pin to Cylinder Head Face 'X' (mm) Connecting Rod Grade Connecting Rod Length (mm)

173.180-173.209 A 151.915-151.964 (151.94)
173.210-173.255 B 151.965-152.035 (152.00)
173.256-173.259 A 151.915-151.964 (151.94)
173.260-173.330 B 151.965-152.035 (152.00)
173.331-173.335 C 152.036-152.095 (152.06)
173.336-173.380 B 151.965-152.035 (152.00)
173.381-173.415 C 152.036-152.095 (152.06)
173.381-173.415 C 152.036-152.095 (152.06)
Piston Pin Dimensions
Description mm
Piston pin length 73.8-74.1
Piston pin diameter 31.995-32.001
Piston pin slide clearance 0.012-0.023
Camshaft Dimensions
Description mm
Camshaft end float 0.014 - 0.200
Camshaft bearing journal diameter 26.440 - 26.465
Camshaft bearing clearance — radial measurement 0.04 - 0.09
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Valve Dimensions
Description mm
Valve stem to valve guide clearance — intake valve 0.0625 - 0.0275
Valve stem to valve guide clearance — exhaust valve 0.0725 - 0.0375
Valve seat width 26
Cylinder Head Dimensions
Description mm
Maximum distortion over 25 mm — measured longitudinally and diagonally 0.025
Maximum distortion over 150 mm — measured longitudinally and diagonally 0.050
Maximum distortion over distance in excess of 150 mm — measured longitudinally and 0.10
diagonally
Peak to valley height of mating surface 0.01
Cylinder head gasket thickness
Piston protrusion of 0.430 - 0.520 mm 1.1 (one hole/tooth)
Piston protrusion of 0.521 - 0.570 mm 1.15 (two
holes/teeth)
Piston protrusion of 0.571-0.620 mm 1.2 (three
holes/teeth)
Oil Pressure Specifications
Description bar
Minimum oil pressure at idle speed 1.25
Minimum oil pressure at 2000 rpm 2.5
Lubricants, Fluids, Sealers and Adhesives (for markets with low sulphur content less than 350 ppm)
Item Specification
Engine Oil WSS-M2C913-C
Lubricants, Fluids, Sealers and Adhesives (for markets with high sulphur content greater than 350 ppm)
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Item Specification
Engine Oil WSS-M2C921-A
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Item Description
1 Turbocharger
2 Exhaust manifold
3 Oil pan
4 Flywheel
5 Vacuum pump
6 Fuel rail
7 Valve cover
8 Intake manifold
9 Thermostat
10 Coolant pump
11 Fuel pump
12 EGR valve
13 Oil cooler
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Item Description
1 VIN (Vehicle identification number)
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Engine - Overview
General View
The 3.2L Duratorq-TDCi (Puma) diesel engine is a five-cylinder inline engine which delivers a power of 147kW
(200 PS).
The engine is additionally equipped with an oil level/oil temperature sensor .
The cylinder head consists of two parts and is made of aluminum. Both parts are bolted to each other.
The lower part contains four valves for each combustion chamber and the two camshafts.
The upper part houses the rocker arm frame with the roller rocker arms. The hydraulic valve clearance
adjustment is integrated in the roller rocker arms.
The camshafts and the fuel injection pump are driven by the crankshaft via the timing chain.
The oil pump is located inside the oil pan and is driven by the crankshaft via a chain.
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NOTE: Cylinder 1 is located on the timing chain end.
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Engine overview
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Item Description
1 Oil pan
2 Oil pan extension
3 Cylinder block
4 Cylinder head lower part
5 Cylinder head upper part
6 Valve cover
Power and torque curves

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Item Description
A Torque (Nm)
B Engine speed (rpm)
C Power (kW)
1 Torque curve for the 147 kW engine (200 PS)
2 Power curve for the 147 kW engine (200 PS)
Engine type identification

Item Description
1 VIN (Vehicle identification number)
On the 3.2L engine the engine code (4 digits) and the engine serial number (2 letters for the year and month and 5
figures for the serial number) are stamped in the cylinder block on the exhaust side (in line with cylinder no. 5).
If the engine or cylinder block is changed, the vehicle identification number must be stamped in the indicated location.
Cylinder head
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Item Description
1 Cylinder head lower part
2 Cylinder head upper part
3 Rocker arm frame
4 Camshafts
5 Roller rocker arms with hydraulic valve clearance adjustment
Electronic turbocharger guide vane adjustment

Item Description
1 Electric actuator for turbocharger guide vane adjustment
Oil level/temperature sensor
An oil level/temperature sensor located on the front of the engine directly beside the engine oil dipstick is provided for
the service interval indicator.
A wire coil that is fitted inside the sensor and continuously supplied with current is used to measure the oil level.
The resistance of the wire coil changes according to how deeply the sensor is immersed in the oil. The measurement
values are registered by the Powertrain Control Module (PCM).
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The change in the voltage drop serves as an input variable for calculating the oil level. The oil temperature is sensed
simultaneously via the integrated temperature sensor. The temperature is used as a corrective factor in the
calculation.
The PCM calculates the next oil change on the basis of an integrated strategy (which also takes into consideration
the mileage and engine operating conditions) and displays it in the instrument panel.
In addition, a separate indicator in conjunction with a corresponding message in the instrument cluster display warns
the driver when the oil quantity falls below the minimum level.
Service instruction
The interval indicator must be reset after an oil change on all vehicles with a diesel engine.
It must be ensured that the vehicle is standing on level ground.
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Diagnosis and Testing Procedure revision date: 10/15/2001
Engine
For additional information, refer to Section 303-00.
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Intake Manifold
Removal
3.
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4.

5.

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6. Torque: 11 Nm

Installation).
2. Torque: 10 Nm
3. Torque: 10 Nm

9.
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10.

11.

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12. NOTE: Replace the o-ring, if necessary.
Torque: 15 Nm

Installation
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Intake Manifold
Removal
3.
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4. Torque: 3 Nm

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5. Torque: 5 Nm

6. Torque: 11 Nm

7. Refer to: Exhaust Gas Recirculation (EGR) Valve - 3.2L Duratorq-TDCi (148kW/200PS) - Puma (303-08C
Engine Emission Control - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation).
8. Torque: 10 Nm

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9.

10.

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1. Torque: 10 Nm
2. Torque: 10 Nm

12.

Installation
2. NOTE: Replace the o-ring, if necessary.
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Torque: 16 Nm

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Camshafts
Plastic Scraper
Materials
Name Specification
Gasket Remover -

Primer -

Engine Oil - SAE 5W-40 WSS-M2C171-E


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Brake Cleaner -

Removal
1. Refer to: Fuel Rail (303-04C Fuel Charging and Controls - 3.2L Duratorq-TDCi (148kW/200PS) - Puma,
Refer to: Valve Cover (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and
Installation).
Refer to: Timing Chain (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and
Installation).
Refer to: Brake Vacuum Pump - RHD (206-07 Power Brake Actuation, Removal and Installation).
2.

3.

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4.

5.

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6.

7.

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8.

9. NOTICE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2-in white, part
number 07528) to clean the sealing surfaces. These tools cause scratches and gouges which make leak
paths. They also cause contamination that causes premature engine failure. Remove all traces of the
gasket.
Make sure that the mating surface is clean and free of foreign material.
Material: Gasket Remover
Material: Brake Cleaner
Material: Primer

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Installation
1. NOTE: The camshafts need to be installed with the slots down aligning with the timing pin holes in the cylinder
head.
Lubricate the camshafts with clean engine oil and install the camshafts.
Material: Engine Oil - SAE 5W-40 (WSS-M2C171-E)

2. NOTE: If the upper cylinder head is not secured within 5 minutes of sealant application, the sealant must be
removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or
10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply a 2 mm bead of silicone sealant on the upper cylinder head.
Material: Primer

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Torque:
Stage 1: 1 - 26 : 7 Nm
Stage 2: 27 : 4 Nm
Stage 3: 1 - 26 : 15 Nm
Stage 4: 27 : 6 Nm
Stage 5: 1 - 26 : 23 Nm
Stage 6: 27 : 10 Nm

4. NOTE: Make sure that the rocker arms do not separate.
NOTE: After the rocker arm assembly is installed, verify that the rocker arms are properly aligned with the
camshafts and the valve stems.
Torque:
Stage 1: 5 Nm
Stage 2: 8 Nm
Stage 3: 10 Nm
Stage 4: 45 °

5. Torque:
M8 bolt : 23 Nm
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M6 nut : 10 Nm

6. Torque: 25 Nm

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7.

8. Torque: 23 Nm

9. Refer to: Fuel Rail (303-04C Fuel Charging and Controls - 3.2L Duratorq-TDCi (148kW/200PS) - Puma,
Refer to: Valve Cover (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and
Installation).
Refer to: Timing Chain (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and
Installation).
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Exhaust Manifold
Removal
3.
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4.

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5. Refer to: Turbocharger - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) -
Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma (303-04D Fuel Charging and Controls - Turbocharger - 2.2L
Refer to: Generator - 3.2L Duratorq-TDCi (Puma) Diesel (414-02 Generator and Regulator, Removal and
Installation).
1. Torque: 9 Nm
2. Torque: 23 Nm
3. Torque: 48 Nm
4. Torque: 23 Nm

7. Remove front RH side wheel only.
8. Torque: 10 Nm

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9. NOTICE: Make sure that new nuts are installed.
NOTICE: Make sure that new bolts are installed.
1. Torque:
Stage 1: 10 Nm
Stage 2: 20 Nm
Stage 3: 35 Nm

10. NOTICE: Make sure that new studs are installed.
Torque: 15 Nm

Installation
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Valve Cover
Removal
2.
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3. Refer to: Fuel Injectors (303-04C Fuel Charging and Controls - 3.2L Duratorq-TDCi (148kW/200PS) - Puma,
1. Torque:
Stage 1: 15 Nm
Stage 2: 30 Nm
2. Torque: 10 Nm

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5.


Installation
2. Torque:
Stage 1: 4 Nm
Stage 2: 10 Nm
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Oil Pump
303-705
Aligner, Oil Pump
Materials
Name Specification

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Removal
Refer to: Oil Pan - 4x2 (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and
Installation).
3.


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1. NOTE: Make sure that the surface is clean and free of foreign material.
2. Install Special Service Tool: 303-705 Aligner, Oil Pump.
3. Torque: 15 Nm

6. NOTE: Do not completely loosen the bolt at this stage.

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7.

Installation
NOTE: Make sure that the installation marks are aligned.
Use Special Service Tool: 303-705 Aligner, Oil Pump.

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2. NOTE: The profile of the special tool must be in contact with the component.
Torque: 10 Nm

NOTE: Make sure that a new component is installed if the O-ring is damaged.

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4. Torque: 10 Nm

NOTE: Make sure that a new component is installed if the O-ring is damaged.

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6. Torque: 13 Nm

Refer to: Oil Pan - 4x2 (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and
Installation).
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Valve Springs
303-060
303-060-05
Adapter for 303-060
303-060-07
Adapter for 303-060
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303-362
Removal
1. Refer to: Valve Cover (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and
Installation).
2.

3. Position the appropriate piston at top dead center (TDC).

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Installation

2. Torque:
Stage 1: 5 Nm
Stage 2: 8 Nm
Stage 3: 10 Nm
Stage 4: 45°

3. Refer to: Valve Cover (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and
Installation).
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Timing Cover
303-428
Separator, Oil Pan
303-682
Materials
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Name Specification

Removal
3. Refer to: Air Cleaner - 3.2L Duratorq-TDCi (Puma) Diesel (303-12C Intake Air Distribution and Filtering - 3.2L
Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation).
4. Refer to: Generator - 3.2L Duratorq-TDCi (Puma) Diesel (414-02 Generator and Regulator, Removal and
Installation).
5. Refer to: Engine Front Seal (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and
Installation).
6.

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7.

8.

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9.

10.

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11. Torque: 23 Nm

12. Torque: 48 Nm

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13.

14. Torque: 23 Nm

15.

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16. Torque:
1: Nm
2: Nm
3: 23 Nm

17. NOTE: Remove RH side wheel only.
18.

19. Torque:
: 20 Nm
: 20 Nm
: 10 Nm
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21.

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Installation
1. NOTICE: Install the timing cover within five minutes of applying the sealer.
NOTE: To remove oil from the cylinder block flange bonderite 1455-w wipes must be used
NOTE: Loctite 7070 or other de-contaminator must not be used on cylinder block flanges.
NOTE: Always apply bonderite 1455 wipes to (4) x t-joints(block/head, block/ladderframe)
NOTE: Apply bonderite 1455-w wipes to (2) x t-joints(head/cam-carrier interfaces)
NOTE: One minute flash time is recommended after bonderite 1455-w application. apply different section of
wipes to each t-joints and do not re-use.
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Install a 3 mm bead of silicone sealant to the T-joints .

3. Using the special tool to align the engine front cover. Install the engine front cover, nuts and bolts.
Use Special Service Tool: 303-682 Aligner, Engine Front Cover.

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Torque:
Stage 1: 5 Nm
Stage 2: 10 Nm
Stage 3: 10 Nm
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Valves
303-060
303-060-05
Adapter for 303-060
303-060-07
Adapter for 303-060
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303-362
Removal
1. Refer to: Cylinder Head (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and
Installation).
2. NOTE: Position a socket on the valve spring seat and gently strike it with a hammer.


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4.

Installation
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Valve Stem Seals
303-508
Removal
1. Refer to: Valve Springs (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and
Installation).
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Installation
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Cylinder Head
205-069
205-070
303-432
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Removal
1. Refer to: Intake Manifold (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and
Installation).
Refer to: Exhaust Gas Recirculation (EGR) Cooler - 2.2L Duratorq-TDCi (118kW/160PS) - Puma (303-08B
Installation).
Refer to: Exhaust Manifold (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and
Installation).
Refer to: Camshafts (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and
Installation).
2.

Installation

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Use Special Service Tool: 205-069 Dial Indicator Gauge (Metric). , 205-070 Holding Fixture, Dial Indicator
Gauge. , 303-432 Holding Fixture, Dial Indicator Gauge (Cylinder Liner Protrusion).

4. NOTE: Note the thickness of the gasket.

5.
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Torque:
Bolts 1 to 12: 10 Nm
Bolts 1 to 12: 90°
Bolts 13 to 22: 90°
Bolts 1 to 12: 90°
Bolts 13 to 22: 90°

7. Refer to: Camshafts (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and
Installation).
Refer to: Exhaust Manifold (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and
Installation).
Refer to: Exhaust Gas Recirculation (EGR) Cooler - 2.2L Duratorq-TDCi (118kW/160PS) - Puma (303-08B
Installation).
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Refer to: Intake Manifold (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and
Installation).
303-254
Materials
Name Specification

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Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
2. Refer to: Flexplate (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation).
3. Refer to: Clutch Disc and Pressure Plate (308-01B Clutch - 6-Speed Manual Transmission - MT82, Removal
and Installation).

All vehicles
5.

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6. NOTICE: Use care when cleaning the sealing surfaces or damage to the foam pads can occur.
Inspect the two foam pads on the ladder frame gaskets.

Installation
All vehicles
If the foam pads are not present on inspection, apply a bead of Silicone Sealant in the location.

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2.

3. NOTE: Install the new crankshaft rear seal carrier within five minutes of applying the recommended sealant.

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installation.
Torque: 10 Nm

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6. Refer to: Clutch Disc and Pressure Plate (308-01B Clutch - 6-Speed Manual Transmission - MT82, Removal
and Installation).

8. Refer to: Flexplate (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation).
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Oil Pan - 4x2
303-428
Separator, Oil Pan
Plastic Scraper
Materials
Name Specification
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Removal
3. Refer to: Steering Gear - LHD RWD (211-02B Power Steering - Vehicles With: Electronic Power Assist
Refer to: Steering Gear - RHD RWD (211-02B Power Steering - Vehicles With: Electronic Power Assist
4. Refer to: Steering Gear - LHD 4WD/LHD RWD (211-02A Power Steering, Removal and Installation).
Refer to: Steering Gear - RHD 4WD/RHD RWD/RHD (211-02A Power Steering, Removal and Installation).
All vehicles

7.
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Installation


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4. Torque:
Stage 1: 7 Nm
Stage 2: 14 Nm

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Torque: 39 Nm

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Oil Pan - 4WD
303-290-01
303-290-03A
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303-290B
Support Bar, Engine
303-428
Separator, Oil Pan
Plastic Scraper
Transmission Jack
Materials
Name Specification

Silicone Sealant WSS-M4G323-A8

Removal

All vehicles

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9.

10. On both sides.

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Installation).

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16.


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18.

Installation

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4. Torque:
Stage 1: 7 Nm
Stage 2: 14 Nm
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Torque: 39 Nm

6. Torque: 25 Nm
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NOTE: Make sure that new nuts are installed.
NOTE: Make sure that new bolts are installed.
Remove the transmission jack.
Torque:
1.: 90 Nm
2.: 265 Nm
3.: 110 Nm

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10.

12. On both sides.
Torque: 175 Nm
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Install the Front axle tube within five minutes of applying the sealer.
Material: Silicone Sealant (WSS-M4G323-A8)

1. Torque: 70 Nm
2. Torque: 40 Nm

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All vehicles
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Engine Front Seal
303-1310
303-679A
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Removal
Installation).
2. 1.Do not completely loosen the crankshaft pulley bolts.

3. NOTICE: Rotate the seal assembly until it releases. Failure to follow this instruction may result in
damage to the seal assembly.

Installation
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2. NOTICE: Rotate the seal assembly until it locks. Failure to follow this instruction may result in damage
to the seal assembly.
NOTE: A new crankshaft front seal carrier is supplied with an alignment sleeve that must not be removed until
the crankshaft rear seal is fully installed.

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4. NOTICE: The crankshaft pulley bolts must not be used more than 3 times.
Torque:
Stage 1: 20 Nm
Stage 2: 45 Nm
Stage 3: 90 Nm
Stage 4: 45°
Stage 5: 45°

Installation).
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Flexplate
303-103 (T74P-6375-A)
Holding Tool, Flywheel
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
Removal).
Removal).
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Install Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.

Installation
Install the flexplate and the new bolts. Tighten in the sequence shown in 3 stages.
Torque:
Stage 1: 25 Nm
Stage 2: 45 Nm
Stage 3: 45 °
Remove Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.

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Installation).
Installation).
Timing Chain
100-010
303-1587
6 mm Drill Bit
2 mm Punch
Removal
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1. Refer to: Timing Cover (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and
Installation).
2. NOTE: When the tool is properly installed, the locating pin will be approximately at the 10 o'clock position.
Using the special tool, set the crankshaft and camshaft positions.
Install Special Service Tool: 303-1587 Timing Tool, Crankshaft.

3. Check the valve timing by inserting the end of 2 drill bits through the sprocket holes into the timing pin holes in
the cylinder head.

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1. Using the special tool, release and hold the ratchet mechanism.
Use Special Service Tool: 100-010 Remover, O-Ring Seal.
2. Compress the tensioner by pushing the timing chain tensioner arm toward the tensioner.
3. Insert the punch into the hole to retain the tensioner.

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6. Remove the bolts and the timing chain tensioner. Discard the timing chain tensioner.

7. Remove the bolts, timing chain tensioner arm and the timing chain guides.

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8. Remove the bolts, camshaft sprockets and the timing chain.

Installation
1. NOTE: Make sure that the timing marks are aligned.
NOTE: Do not tighten the bolts at this time.
Install the timing chain, camshaft sprockets and the bolts.

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2. Install the timing chain tensioner arm and the timing chain guides and the bolts.
Torque:
1: 14 Nm
2: 31 Nm
3: 40 Nm

3. Install the timing chain tensioner and bolts. Remove the retaining pin.
Torque: 15 Nm

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the cylinder head. Tighten the bolts for the camshaft sprockets.
Torque:
Stage 1: 12 Nm
Stage 2: 33 Nm

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Rotate the engine two revolutions.

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the cylinder head. If the drill bit ends can not be inserted repeat the timing steps.


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11. Refer to: Timing Cover (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and
Installation).
303-122
Transmission Jack
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6. Refer to: Engine Undershield (501-02 Front End Body Panels, Removal and Installation).
8.

9.

10. Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
11.
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12. On both sides.

13.

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14.

15.

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16.

17. Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
Refer to: Powertrain Control Module (PCM) (303-14A Electronic Engine Controls - 2.5L Duratec-HE
20.

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21.

22.

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23. Torque: 5 Nm

Installation).
25. Refer to: Radiator (303-03C Engine Cooling - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and
Installation).
27.

29.
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30.

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All vehicles
34.

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36.

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37.

39. Torque: 4 Nm

40. Torque: 10 Nm
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41.

42.

43.
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retaining straps.

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45.

46.

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47. On both sides.


49.

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50.

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303-122
307-346 (T97T-7902-A)
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Transmission Jack
7.

8.

11.
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12. On both sides.

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13.

14.

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15.

19.

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20.

21.

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22. Torque: 5 Nm

Installation).
Installation).
26.

28.
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30.

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34.

35.

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36.

38. Torque: 4 Nm

39. Torque: 10 Nm
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40.

41.

42.
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retaining straps.

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44.

45.

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46.

47.

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48. On both sides.


50.

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51. Install Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.

52.

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Engine Accessories
303-122
303-1310
303-1317
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303-249
Remover, Crankshaft Timing Pulley
303-254
303-435
Mounting Stand
303-435-06
303-435-11B
303-679A

2.
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3.

4.
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5.

6.
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7. Install Special Service Tool: 303-435-11B Mounting Plate for 303-435-06.

8. Install Special Service Tool: 303-435-06 Mounting Bracket for 303-435. , 303-435 Mounting Stand.
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11.
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13.
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All vehicles
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15.

16.

17.
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18.

19.

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21.

22.

23.
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24.
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25.

26.

27.
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29.

30.
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31.

32.
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33.


35. NOTE: Do not loosen the bolts more than 2 turns.
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37.
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38.

39.
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NOTICE: Make sure that the high-pressure fuel supply line remains in contact with both the fuel pump and
the fuel rail until both unions have been detached and cleaned.

41.

42.
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43.

44.

45.
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46.


48.
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49. Use Special Service Tool: 303-1317 Locking Tool, Fuel Injection Pump Sprocket.

50.

51.
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52.

53.

54.
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55. Use Special Service Tool: 303-249 Remover, Crankshaft Timing Pulley. , 303-1317 Locking Tool, Fuel Injection
Pump Sprocket.

56. Remove Special Service Tool: 303-249 Remover, Crankshaft Timing Pulley.
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57. Use Special Service Tool: 303-1317 Locking Tool, Fuel Injection Pump Sprocket.

58.

59.
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60.

61.
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62.

63. Use Special Service Tool: 303-1310 Holding Wrench, Crankshaft.

64. NOTICE: Rotate the seal assembly until it releases. Failure to follow this instruction may result in damage to
the seal assembly.
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Disassembly Procedure revision date: 05/12/2015
Engine
303-428
Separator, Oil Pan
2. Refer to: Engine Accessories (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Installation).
3.
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5.

6.

7.

8.
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10.

11.
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12.

13.

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Cylinder Head
Disassembly
1.
For additional information, refer to: Valves (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma,
2. Torque : 13Nm
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3. Torque : 23Nm

Assembly
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Piston
Materials
Name Specification

DISASSEMBLY
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.
1. Remove and discard the piston rings.
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2. Remove and discard the piston pin retainers. Remove the piston pin.

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3. Separate the piston from the connecting rod. Clean and inspect the piston.

ASSEMBLY
1. NOTE: Align the piston-to-connnecting rod orientation marks made during disassembly.
Align the front of the piston and connecting rod. Assembly the piston and the connecting rod.
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2. Lubricate with clean engine oil and install the piston pin.

3. Install the piston pin retainers.

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4. NOTE: The rings are to be fitted with the paint mark to the left of the piston ring gap.
NOTE: The upper and lower compression ring gaps are the be installed 180 degrees apart.
NOTE: The oil control ring position is not controlled.
Lubricate with clean engine oil and install the piston rings.

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Assembly Procedure revision date: 08/20/2015
Engine
100-002 (TOOL-4201-C)
Holding Fixture with Dial Indicator Gauge
205-044
205-069
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303-1562
Timing Tool
303-1587
303-254
303-428
Separator, Oil Pan
303-432
303-682
303-698
Piston Ring Compressor
Materials
Name Specification


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1. NOTE: The cylinder block oil filter must be installed flush to 0.04 inch (1 mm) underflush.
Install the cylinder block oil filter.

2. NOTE: The piston cooling nozzles must be fully inserted before installing the bolt.
Install the piston cooling nozzles and new bolts.
Torque: 10 Nm

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3. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted
during disassembly.
NOTE: Verify that the hole in the bearings aligns with the oil gallery in the cylinder block.
Install the crankshaft upper bearings. Lubricate with clean engine oil

4. Lubricate with clean engine oil and install the crankshaft.

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Torque:
Stage 1: 6 Nm
Stage 2: 15 Nm
Stage 3: 20 Nm
Stage 4: 35 Nm
Stage 5: 80 Nm
Stage 6: 90°

7. Using the special tool, check the crankshaft end play.
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8. If necessary, position the crankshaft sprocket washer.

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9. If necessary, install the crankshaft sprocket and bolt.
Torque: 36 Nm

10. NOTE: Care must be taken not to damage the piston cooling nozzles while doing the measuring.
NOTE: Failure to have the crankshaft connecting rod journal at TDC (top dead center) may result in the
incorrect selection of connecting rod.
Position the crankshaft connecting rod journal at TDC for the cylinder that is being measured. Using a
commercially available Depth Gauge, measure the crankshaft connecting rod journal to cylinder block deck
measurement on all cylinder bores.

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11. Select the appropriate connecting rod grade using the crank pin to cylinder head face value 'X' from the
Connecting Rod Grade Selection table.
12. If any of the connecting rods need to be replaced.
Refer to: Piston (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Disassembly and Assembly
of Subassemblies).
Use the General Equipment: Piston Ring Compressor

14. NOTE: If reusing the connecting rod bearings, install them in their original positions and orientation as noted
during disassembly.
Install the connecting rod bearings. Lubricate with clean engine oil.

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Torque:
Stage 1: 8 Nm
Stage 2: 25 Nm
Stage 3: 60 Nm
Stage 4: 90°

17. Using the special tool, check the piston protrusion. If not within specifications, repeat the connecting rod length
calculation.
Refer to: Specifications (303-01B) .
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18.

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20. Using a straight edge, align the rear surface of the ladderframe with the rear surface of the engine block. The
rear clearance does not exceed 0.05 mm gap.

21. Using a straight edge, align the side surface of the ladderframe with the side surface of the engine block. The
side clearance does not exceed 0.01mm overlap.

22. Torque:
Stage 1: 6 Nm
Stage 2: 23 Nm
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24. Take a reference measurement from the front face of the crankshaft sprocket.
(Metric).

25. Take measurements at two different points on the oil pump sprocket and align the oil pump sprocket.
(Metric).
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26. Torque:
1: 10 Nm
2: 13 Nm

27. Torque: 10 Nm

28. NOTE: A new crankshaft rear seal carrier is supplied with an alignment sleeve that must not be removed until
the crankshaft rear seal is fully installed. Failure to follow this instruction may result in damage to the vehicle.
Clean the area on the engine before installing a new crankshaft rear seal carrier.
Check the two foam pads are located as shown on the ladder frame gasket.
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29. Material: Engine Oil - SAE 5W-30 (WSS-M2C913-C)

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Failure to follow this instruction may result in damage to the vehicle.
area shown.


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installation.
Torque:
:
Stage 1: 5 Nm
Stage 2: 10 Nm

33. NOTE: Make sure that the flywheel is in full contact with the crankshaft flange before installing the flywheel
bolts.

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34. NOTICE: Make sure that the flywheel is in full contact with the crankshaft flange before installing the
flywheel bolts.
Use Special Service Tool: 303-254 Locking Tool, Flywheel.
Torque:
Stage 1: 25 Nm
Stage 2: 40 Nm
Stage 3: 45°

35. Use Special Service Tool: 303-1587 Timing Tool, Crankshaft.

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Torque: 20 Nm

39. Torque: 8 Nm
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Torque: 20 Nm
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43. Torque: 8 Nm

All vehicles

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Using the special tools, measure the piston protrusion.

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47. Determine the cylinder head gasket.

49.

Torque:
Stage 1: 1-12: 10 Nm
Stage 2: 13-22: 5 Nm
Stage 3: 1-12: 20 Nm
Stage 4: 13-22: 10 Nm
Stage 5: 1-12: 35 Nm
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Stage 6: 13-22: 20 Nm
Stage 7: 1-12: 45 Nm
Stage 8: 13-22: 26 Nm
Stage 9: 1-12: 90°
Stage 10: 13-22: 90°
Stage 11: 1-12: 90°
Stage 12: 13-22: 90°

51. Material: Silicone Sealant (WSE-M4G323-A4)

52. Torque:
Stage 1: 1-26: 7 Nm
Stage 2: 27-28: 4 Nm
Stage 3: 1-26: 15 Nm
Stage 4: 27-28: 6 Nm
Stage 5: 1-26: 23 Nm
Stage 6: 27-28: 10 Nm
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53. Torque:
Stage 1: 5 Nm
Stage 2: 8 Nm
Stage 3: 10 Nm
Stage 4: 45°

54. Tighten the fuel injection pump bracket nut and bolts. Tighten in the sequence shown.
Torque:
Stage 1: 22 Nm
Stage 2: 10 Nm
Stage 3: 22 Nm

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55. Torque: 45 Nm

56.

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Torque:
Stage 1: 12 Nm
Stage 2: 24 Nm

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59. NOTE: Make sure that new bolts are installed.
Torque:
1: 14 Nm
2: 31 Nm
3: 15 Nm

Torque: 15 Nm

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64. Check the position of the timing marks and correct if necessary.

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67.

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68. Torque:
stage 1: 4 Nm
stage 2: 10 Nm

Install the new engine front cover gasket.

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Torque:
Stage 1: 5 Nm
Stage 2: 10 Nm

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74. Torque:
Stage 1: 6 Nm
Stage 2: 13 Nm
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Torque: 35 Nm

76. Refer to: Engine Accessories (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Installation).
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303-122
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3.


5. NOTE: Hand tighten the nuts at this stage.
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Torque: 48 Nm

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Torque: 48 Nm

9. Torque: 80 Nm

1. Torque: 48 Nm
2. Torque: 25 Nm
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11. Torque: 80 Nm


13. Torque: 13 Nm
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14.

15. Torque: 12 Nm

16. Torque: 4 Nm
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17. Torque: 10 Nm


19. Torque: 22 Nm

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20.

21.

3. Torque: 35 Nm
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23.

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All vehicles
24. Torque: 22 Nm

25. Refer to: Starter Motor - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) -
Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma (303-06 Starting System - 2.2L Duratorq-TDCi
26.

28. Refer to: Radiator (303-03 Engine Cooling - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
29. Refer to: Air Cleaner - 2.2L Duratorq-TDCi (Puma) Diesel (303-12 Intake Air Distribution and Filtering - 2.2L
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30.

31.

32. Torque: 10 Nm

33. Torque: 18 Nm
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34. Torque: 5 Nm

35.

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36.

Refer to: Powertrain Control Module (PCM) (303-14B Electronic Engine Controls - 2.2L Duratorq-TDCi
40. Torque: 10 Nm

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41. Torque: 10 Nm

42. On both sides.

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43. On both sides.

44. Torque: 10 Nm

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52. Refer to: Power Steering System Filling (211-00 Steering System - General Information, General Procedures).
Refer to: Power Steering System Bleeding (211-00 Steering System - General Information, General
Procedures).
53. Refer to: Fuel System Bleeding (310-00B Fuel System - General Information - 2.2L Duratorq-TDCi
Puma, General Procedures).
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303-122
307-346 (T97T-7902-A)
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Materials
Name Specification
Grease - Electrical Contact WSB-M1C239-A


3. NOTICE: Prior to installation of the engine, the torque converter pilot hub must be lubricated with
multipurpose grease or damage to the torque converter or the engine crankshaft can occur.
Lubricate the torque converter pilot hub with multipurpose grease.
Material: Grease - Electrical Contact (WSB-M1C239-A)

4. Remove Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.
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5. NOTE: Make sure that the torque converter remains in the transmission.

2. NOTE: Make sure that the transmission is installed straight in relation to the engine to prevent damage
to the pilot bearing.

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1. NOTE: Make sure that the component is correctly located on the locating dowels.
2. Only tighten the nut finger tight at this stage.
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9. NOTE: Only tighten the nut and bolts finger tight at this stage.

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Torque: 48 Nm

Torque: 48 Nm

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13. Torque: 80 Nm

1. Torque: 48 Nm
2. Torque: 48 Nm

15. Torque: 80 Nm
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17. Torque: 13 Nm

18. Torque: 40 Nm
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19. Torque: 22 Nm

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20.

21. Torque: 12 Nm

22. Torque: 4 Nm

23. Torque: 10 Nm
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25. Torque: 22 Nm

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26.

27.

3. Torque: 35 Nm
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29.

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All vehicles
30. Torque: 22 Nm

32.

Installation).
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Installation).
38.

39.

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40. Torque: 18 Nm

41. Torque: 5 Nm

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42.

43.

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46. Torque: 10 Nm

47. Torque: 10 Nm

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48. On both sides.

49. On both sides.

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50. Torque: 10 Nm

58. Refer to: Power Steering System Bleeding (211-00 Steering System - General Information, General
Procedures).
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Engine Accessories
303-122
303-1310
303-1317
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303-254
303-435
Mounting Stand
303-435-06
303-435-11B
303-679A
308-204
Materials
Name Specification

1.
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2. NOTE: Install new crankshaft rear seal carrier with in five minutes after applying the recomended sealent. Failure to
follow this instruction may result in damage to the vehicle.
NOTE: Do not add any more than the specified quantity of sealant or add the sealant anywhere other than the area
shown.

3. NOTICE: A new crankshaft rear seal carrier is supplied with an alignment sleeve that must not be removed
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until the crankshaft rear seal is fully installed. Failure to follow this instruction may result in damage to the
vehicle.

installation.
Torque:
Stage 1: 5 Nm
Stage 2: 10 Nm

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6. NOTE: Make sure that the flywheel is in full contact with the crankshaft flange before installing the flywheel bolts.

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Torque:
Stage 1: 25 Nm
Stage 2: 45 Nm
Stage 3: 45°


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10. NOTICE: Tighten the clutch pressure plate retaining bolts by two turns at a time in the sequence shown.
Torque: 30 Nm

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12.

13. Torque: 23 Nm
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14.

15. Torque: 23 Nm

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18.

19.
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20. Torque: 23 Nm

21. Torque: 10 Nm

22. Torque: 23 Nm
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23. Torque: 23 Nm

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1. Torque: 48 Nm
2. Torque: 23 Nm

25. Torque: 48 Nm


27. NOTICE: Rotate the seal assembly until it locks. Failure to follow this instruction may result in damage to the
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seal assembly.
NOTE: A new crankshaft front seal carrier is supplied with an alignment sleeve that must not be removed until the
crankshaft rear seal is fully installed.


29. NOTICE: Crankshaft pulley retaining bolts must only be used three times.
Torque:
Stage 1: 20 Nm
Stage 2: 45 Nm
Stage 3: 90 Nm
Stage 4: 45°
Stage 5: 45°

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30. Torque: 10 Nm

31. Torque: 8 Nm

32.

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33. Torque:
Stage 1: 5 Nm
Stage 2: 13 Nm
Stage 3: 16 Nm

34. Record the new fuel injector correction factor code.

35. NOTE: Using a socket (or similar), press the new fuel injector copper seals onto the fuel injectors making sure that
the copper seals are pushed fully home to prevent uneven clamping.

Torque:
Bolt 1 and 4.:
Stage 1: 6 Nm
Stage 2: 360°
Bolt 2.: 3 Nm
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Bolt 3.:
Stage 3: 4 Nm
Stage 4: 360°

37. Torque:
Stage 1: 720°
Stage 2: 23 Nm

Vacuum foreign material from the high-pressure fuel supply line, the fuel pump and the fuel rail.
Refer to: Fuel Injection Component Cleaning (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi
(88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma,
General Procedures).
Torque:
Fuel rail high-pressure fuel supply line unions:
Stage 1: 5 Nm
Stage 2: 35 Nm
Fuel rail high-pressure fuel supply line bracket bolt: 10 Nm
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39.

Vacuum foreign material from the low-pressure fuel supply line and fuel return line.
Refer to: Fuel Injection Component Cleaning (303-04B Fuel Charging and Controls - 2.2L Duratorq-TDCi
(88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma,
General Procedures).

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41. Torque:
Stage 1: 15 Nm
Stage 2: 30 Nm

42.

43. NOTICE: Align the camshaft and vacuum pump couplings correctly or damage to the camshaft or vacuum
pump may occur.

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1. NOTE: Before fitting bolts, check that the vacuum pump couple drive and camshaft keyway are aligned. If a
gap is present between vacuum pump and cylinder head, do not fit and run bolts.
NOTE: Under no circumstances should the retaining bolts be tightened if a gap between pump and head
faces is present.

45. Torque: 23 Nm

46. Torque: 23 Nm
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47.

48. Torque: 10 Nm

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50.

2. Torque: 10 Nm
3. Torque: 10 Nm

52.
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53.

54.
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55.


57. Torque:
Bolt 1.:
Stage 1: 10 Nm
Stage 2: 20 Nm
Stage 3: 35 Nm
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58. Torque: 9 Nm

59. Torque: 20 Nm

60. Torque: 25 Nm
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61. Torque:
Bolt 1 and 2.: 48 Nm
Bolt 3 and 4.: 23 Nm

4. Torque: 15 Nm
5. Torque: 48 Nm
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64.

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66.

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68. Remove Special Service Tool: 303-435-06 Mounting Bracket for 303-435. , 303-435 Mounting Stand.

69. Remove Special Service Tool: 303-435-11B Mounting Plate for 303-435-06.

70. Torque: 10 Nm
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71. Torque: 23 Nm

72.
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73. Torque: 10 Nm

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1. Torque: 20 Nm
2. Torque: 20 Nm

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303-01A Engine - 2.

Crank Pin to Cylinder Head Face 'X' (mm) Connecting Rod Grade Connecting Rod Length (mm)

Item Part Number Description

Item Part Number Description

Crank Pin to Cylinder Head Face 'X' (mm) Connecting Rod Grade Connecting Rod Length (mm)

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