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Engine: 303-01C Engine - 3.2L Duratorq-Tdci (148Kw/200Ps) - Puma 2011 - 2014 Ranger Assembly
Engine: 303-01C Engine - 3.2L Duratorq-Tdci (148Kw/200Ps) - Puma 2011 - 2014 Ranger Assembly
Engine
100-002 (TOOL-4201-C)
Holding Fixture with Dial Indicator Gauge
205-044
Holding Fixture, Dial Indicator Gauge
205-069
Dial Indicator Gauge (Metric)
303-1562
Timing Tool
303-1587
Timing Tool, Crankshaft
303-254
Locking Tool, Flywheel
303-428
Separator, Oil Pan
303-432
Holding Fixture, Dial Indicator Gauge (Cylinder Liner Protrusion)
303-682
Aligner, Engine Front Cover
303-698
Timing Tool, Crankshaft
Name Specification
Silicone Sealant WSE-M4G323-A4
1. NOTE: The cylinder block oil filter must be installed flush to 0.04 inch (1 mm) underflush.
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2. NOTE: The piston cooling nozzles must be fully inserted before installing the bolt.
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
Material: Engine Oil - SAE 5W-30 (WSS-M2C913-C)
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5. NOTE: Make sure that these components are installed to the noted removal position.
6. NOTE: Make sure that these components are installed to the noted removal position.
NOTE: Install all the bolts finger tight before final tightening.
Torque:
Stage 1: 6 Nm
Stage 2: 15 Nm
Stage 3: 20 Nm
Stage 4: 35 Nm
Stage 5: 80 Nm
Stage 6: 90°
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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.
Refer to: Specifications - Vehicles Built From: 17-August-2015 (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Specifications).
13. NOTE: Make sure that these components are installed to the noted removal position.
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.
Material: Engine Oil - SAE 5W-30 (WSS-M2C913-C)
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15. NOTE: Make sure that these components are installed to the noted removal position.
16. NOTE: Make sure that these components are installed to the noted removal position.
NOTE: Install all the bolts finger tight before final tightening.
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 - Vehicles Built Up To: 16-August-2015 (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, Specifications).
Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
18.
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19. NOTE: Only tighten the bolts finger tight at this stage.
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.
Use Special Service Tool: 303-432 Holding Fixture, Dial Indicator Gauge (Cylinder Liner Protrusion).
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.
Use Special Service Tool: 303-432 Holding Fixture, Dial Indicator Gauge (Cylinder Liner Protrusion).
22. Torque:
Stage 1: 6 Nm
Stage 2: 23 Nm
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23. NOTE: Only tighten the bolts finger tight at this stage.
24. 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).
25. Take measurements at two different points on the oil pump sprocket and align the oil pump sprocket.
Use Special Service Tool: 205-044 Holding Fixture, Dial Indicator Gauge. , 205-069 Dial Indicator Gauge (Metric).
26. Torque:
1: 10 Nm
2: 13 Nm
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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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30. 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.
NOTE: If the foam pads are not present on inspection, fill the square areas shown with 75% of sealant.
31. 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.
32. NOTE: New crankshaft rear seal carriers are supplied with an alignment sleeve which must be removed after installation.
Torque:
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:
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.
34. NOTICE: Make sure that the flywheel is in full contact with the crankshaft flange before installing the flywheel bolts.
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37. NOTE: Make sure that the special tool is located in the flywheel timing slot.
39. Torque: 8 Nm
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41. NOTE: Make sure that the special tool is located in the flexplate timing slot.
43. Torque: 8 Nm
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All vehicles
44. 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.
45. 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.
46. NOTE: The largest measurement determines the choice of the cylinder head gasket.
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49.
50. NOTICE: Make sure that new cylinder head bolts are installed.
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
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°
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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
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.
58. NOTE: Make sure that the installation marks are aligned.
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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.
67.
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68. Torque:
stage 1: 4 Nm
stage 2: 10 Nm
70. NOTE: The component must be installed within 5 minutes of applying the sealant.
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71. Use Special Service Tool: 303-682 Aligner, Engine Front Cover.
Torque:
Stage 1: 5 Nm
Stage 2: 10 Nm
73. NOTICE: Install the oil pan within five minutes of applying the sealer.
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74. Torque:
Stage 1: 6 Nm
Stage 2: 13 Nm
Torque: 35 Nm
76. Refer to: Engine Accessories (303-01 Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma) .
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