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303-01D Engine - 2.2L Duratorq-TDCi (114k W/155PS) (UY)/2.2L Duratorq-TDCi (74k W/100PS) – 2014 - 2019
Puma/2.2L Duratorq-TDCi (92k W/125PS) – Puma/2.2L Duratorq-TDCi (99k W/135PS) – Puma/2.2L Transit
Duratorq-TDCi (114k W/155PS) – Puma, LHD 4WD/LHD RWD/RHD 4WD/RHD RWD
Procedure
Assembly revision date:
07/6/2021

Engine

Special Tool(s) / General Equipment

205-044
Holding Fixture, Dial Indicator Gauge

205-069
Dial Indicator Gauge (Metric)

205-070
Holding Fixture, Dial Indicator Gauge

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

Plastic Scraper
Dowel with a Diameter of 6 mm
Round-Ended Steel Rule
6 mm Drill Bit
Piston Ring Compressor

Materials

Name Specification
RTV Silicone Sealant WSE-M4G323-A6

Primer -

1. NOTE: Mak e sure that the components are installed to the position noted before removal.

NOTE: Component(s) must be lubricated with clean engine oil.

Authoring Template
Torque: 10 Nm

2. NOTE: Mak e sure that the components are installed to the position noted before removal.

NOTE: Component(s) must be lubricated with clean engine oil.

3. NOTE: Mak e 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°

4. NOTE: Component(s) must be lubricated with clean engine oil.

Use the General Equipment: Piston Ring Compressor

5. NOTE: Component(s) must be lubricated with clean engine oil.

NOTE: Mak e sure that these components are installed to the noted removal position.

6. NOTE: Mak e 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: 37 Nm
Stage 4: 90°
7. If necessary, position the crankshaft sprocket washer.

8. If necessary, install the crankshaft sprocket and bolt.

Torque: 36 Nm
 9.

10. NOTE: Only tighten the bolts finger tight at this stage.
11. The ladder frame and the cylinder block must be aligned so that the side clearance does not exceed 0.05 mm
overlap to 0.05 mm gap.
Use Special Service Tool: 303-432 Holding Fixture, Dial Indicator Gauge (Cylinder Liner Protrusion).

12. The ladder frame and the cylinder block must be aligned so that the rear clearance does not exceed 0.01 mm
overlap to 0.2 mm gap.
Use the General Equipment: Round-Ended Steel Rule
13. Torque:
Stage 1: 6 Nm
Stage 2: 23 Nm
Stage 3: 23 Nm

14. NOTE: Only tighten the bolts finger tight at this stage.

Torque:
1:: 13 Nm
2:: 10 Nm
15. 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).

16. 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).
17. Torque: 10 Nm

18.

19.

1. Use the General Equipment: Plastic Scraper

 2. NOTE: Mak e sure that the mating faces are clean and free of foreign material.

Material: Primer

20. NOTE: Do not remove the alignment sleeve from the crank shaft rear seal prior to installation on the crank shaft.

NOTE: Mak e sure that a new component is installed.

NOTE: Mak e sure that the mating faces are clean and free of foreign material.

21. NOTE: Mak e sure that the mating faces are clean and free of foreign material.
22. NOTE: The component must be installed within 5 minutes of applying the sealant.

Material: RTV Silicone Sealant (WSE-M4G323-A6)

23. NOTE: The new crank shaft rear seal is supplied with an alignment sleeve which must be removed after
installation.

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

25. NOTE: Mak e 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.

26. 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: 15 Nm
Stage 2: 50 Nm
Stage 3: 65 Nm
Stage 4: 45°

27. 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.
28. 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.

29. NOTE: The largest measurement determines the choice of the cylinder head gask et.

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).
30. NOTE: Mak e sure that a new component is installed.

Determine the cylinder head gasket.

Refer to: Specifications (303-01C Engine - 2.2L Duratorq-TDCi (74kW/100PS) – Puma/2.2L Duratorq-TDCi
(92kW/125PS) – Puma/2.2L Duratorq-TDCi (99kW/135PS) – Puma/2.2L Duratorq-TDCi (114kW/155PS) – Puma,
LHD FWD/RHD FWD, Specifications).

31.
32. NOTICE: Make sure that no fluids are present in the cylinder head bolt threaded bores.

NOTICE: Make sure that new bolts are installed.

NOTE: Install all the bolts finger tight before final tightening.

1. Torque:
1-10: 10 Nm
2. Torque:
11-18: 5 Nm
3. Torque:
1-10: 20 Nm
4. Torque:
11-18: 10 Nm
5. Torque:
1-10: 35 Nm
6. Torque:
11-18: 20 Nm
7. Torque:
1-10: 45 Nm
8. Torque:
11-18: 25 Nm
9. Torque:
1-10: 90°
10. Torque:
11-18: 90°
11. Torque:
1-10: 90°
12. Torque:
11-18: 90°
33. Material: RTV Silicone Sealant (WSE-M4G323-A6)

34. Torque:
Bolts 1 to 22:
Stage 1: 7 Nm
Stage 2: 15 Nm
Stage 3: 23 Nm
Bolts 23 to 24:
Stage 4: 4 Nm
Stage 5: 6 Nm
Stage 6: 10 Nm
35. Torque:
Stage 1: 10 Nm
Stage 2: 30°

36. Torque: 23 Nm
37. Torque: 55 Nm

38. Torque: 23 Nm

39. NOTE: Do not fully tighten the crank shaft position sensor brack et retaining bolts at this stage.
40. Install Special Service Tool: 303-1587 Timing Tool, Crankshaft.

41. NOTICE: Do not turn the crankshaft when the special tool is fully located into the flywheel. Failure to
follow this instruction will cause damage to the CKP sensor hole.

NOTE: Rotate the crank shaft in the normal direction of rotation to the mark of the calculated 50 degrees BTDC.

NOTE: Mak e sure that the special tool is fully located in the flywheel so that the engine cannot be rotated in either
direction.

Use Special Service Tool: 303-698 Timing Tool, Crankshaft.

Torque: 25 Nm

42. Remove Special Service Tool: 303-698 Timing Tool, Crankshaft.

43. NOTE: Mak e sure that the installation mark s are aligned.

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

Use the General Equipment: 6 mm Drill Bit

44. NOTICE: Make sure that new bolts are installed.

1. Torque: 15 Nm
2. Torque: 40 Nm
45. NOTE: Mak e sure that a new component is installed.

remove the tensioner timing pin

Torque: 15 Nm

46. Torque: 35 Nm
47. Remove the General Equipment: Dowel with a Diameter of 6 mm

48. Remove Special Service Tool: 303-1587 Timing Tool, Crankshaft.

49.

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

51. Check the camshaft timing by inserting the 6 mm dowels through the holes in the camshaft sprockets and correct
if necessary.
Use the General Equipment: Dowel with a Diameter of 6 mm

52. Remove Special Service Tool: 303-1587 Timing Tool, Crankshaft.

53. Remove the General Equipment: Dowel with a Diameter of 6 mm

54. NOTE: Mak e sure that a new component is installed.

Torque: 7 Nm
55. Torque:
Stage 1: 4 Nm
Stage 2: 10 Nm
Stage 3: 11 Nm

56. NOTE: Mak e sure that a new component is installed.

57. NOTE: Mak e sure that the mating faces are clean and free of foreign material.

NOTE: The component must be installed within 5 minutes of applying the sealant.

NOTE: Mak e sure that a new component is installed.

 Material: RTV Silicone Sealant (WSE-M4G323-A6)

58. Use Special Service Tool: 303-682 Aligner, Engine Front Cover.
Torque:
1: 10 Nm
2: 10 Nm
59.

60. Torque:
1:: 23 Nm
2:: 23 Nm
61. NOTE: Do not damage the mating faces.

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

62. NOTICE: Install the oil pan within five minutes of applying the sealer.

Material: RTV Silicone Sealant (WSE-M4G323-A6)

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

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