303-01B Motor 2.2 Duratorq

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-1 303-01B-1 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma . SECTION 303-01B Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma VEHICLE APPLICATION: 2011.50 Ranger CONTENTS SPECIFICATIONS Specifications...................................................................................................................... Engine Data – 120 PS................................................................................................... Engine Data – 125 PS................................................................................................... Engine Data – 150 PS................................................................................................... Engine Oil Capacity........................................................................................................ Cylinder Block Dimensions............................................................................................. Piston Dimensions.......................................................................................................... Crankshaft Dimensions................................................................................................... Connecting Rod Dimensions.......................................................................................... Piston Pin Dimensions.................................................................................................... Camshaft Dimensions..................................................................................................... Valve Dimensions........................................................................................................... Cylinder Head Dimensions............................................................................................. Oil Pressure Specifications............................................................................................. DESCRIPTION AND OPERATION Engine (Overview).............................................................................................................. General............................................................................................................................... Features............................................................................................................................. Fuel system........................................................................................................................ Engine management.......................................................................................................... Engine-emission control .................................................................................................... Diagnosis ........................................................................................................................... Specification ...................................................................................................................... Overview of the main engine components......................................................................... Engine................................................................................................................................. REMOVAL AND INSTALLATION Camshafts...................................................................................................... Crankshaft Front Seal..................................................................................... Crankshaft Rear Seal..................................................................................... Cylinder Head................................................................................................. Exhaust Manifold............................................................................................ Intake Manifold............................................................................................... Timing Cover.................................................................................................. Oil Pan............................................................................................................ Oil Pump......................................................................................................... Valves................................................................................................................................. Valve Cover.................................................................................................... Valve Stem Seals........................................................................................... Valve Springs...................................................................................................................... PAGE 303-01B-3 303-01B-3 303-01B-3 303-01B-3 303-01B-4 303-01B-4 303-01B-4 303-01B-4 303-01B-5 303-01B-5 303-01B-5 303-01B-5 303-01B-5 303-01B-5 303-01B-7 303-01B-7 303-01B-7 303-01B-7 303-01B-7 303-01B-7 303-01B-7 303-01B-7 303-01B-9 303-01B-10 (21 284 0) 303-01B-13 (21 467 0) 303-01B-17 (21 468 4) 303-01B-20 (21 163 0) 303-01B-23 (21 187 0) 303-01B-26 (21 183 0) 303-01B-27 (21 146 0) 303-01B-29 (21 154 0) 303-01B-34 (21 714 0) 303-01B-39 303-01B-42 (21 141 0) 303-01B-44 (21 238 0) 303-01B-46 303-01B-47

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-2 303-01B-2 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma . REMOVAL Engine – Vehicles With: 5-Speed Manual Transmission - MT75.................. Engine – Vehicles With: 6-Speed Manual Transmission - MT82.................. Engine – Vehicles With: 6-Speed Automatic Transaxle - 6R80.................... Engine Accessories........................................................................................ DISASSEMBLY Engine............................................................................................................ DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Cylinder Head................................................................................................. ASSEMBLY Engine............................................................................................................ INSTALLATION Engine – Vehicles With: 5-Speed Manual Transmission - MT75.................. Engine – Vehicles With: 6-Speed Manual Transmission - MT82.................. Engine – Vehicles With: 6-Speed Automatic Transaxle - 6R80.................... Engine Accessories........................................................................................ (21 132 0; 21 132 6; 21 132 7) 303-01B-49 (21 132 0; 21 132 6; 21 132 7) 303-01B-58 (21 132 0; 21 132 6; 21 132 7) 303-01B-67 (21 139 4) 303-01B-77 (21 134 8) 303-01B-89 (21 165 6) 303-01B-95 (21 134 8) 303-01B-96 (21 132 0; 21 132 6; 21 132 7) 303-01B-110 (21 132 0; 21 132 6; 21 132 7) 303-01B-119 (21 132 0; 21 132 6; 21 132 7) 303-01B-128 (21 139 4) 303-01B-138

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-3 303-01B-3 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma SPECIFICATIONS Engine Data – 120 PS Description Code Firing order Bore diameter Stroke Displacement Compression ratio compression pressure value Power output at _ rpm Torque between 1500 to 2200 rpm Idle speed Engine Data – 125 PS Description Code Firing order Bore diameter Stroke Displacement Compression ratio compression pressure value Power output at _ rpm Torque between 1500 to 2200 rpm Idle speed Engine Data – 150 PS Description Code Firing order Bore diameter Stroke Displacement Compression ratio compression pressure value Power output at _ rpm Torque between 1500 to 2200 rpm Idle speed *%9$-3) 1-3-4-2 86 mm 94.6 mm 2198 cc 88 kW (120 PS) Nm USP *%9$-4: 1-3-4-2 86 mm 94.6 mm 2198 cc 92 kW (125 PS) Nm USP *%9$-4- 1-3-4-2 86 mm 94.6 mm 2198 cc 110 kW (150 PS) Nm USP

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-4 303-01B-4 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma SPECIFICATIONS Engine Oil Capacity Description Initial fill including oil filter Service fill including oil filter Cylinder Block Dimensions Description Cylinder bore diameter – Class A Cylinder bore diameter – Class B Cylinder bore diameter – Class C Main bearing shells 1 to 4 inner diameter – bearings installed Main bearing shell 5 inner diameter – bearings installed Main bearings 1 to 4 radial clearance Main bearing 5 radial clearance Main bearings 1 to 4 parent bore diameter – vertical measurement Main bearing 5 parent bore diameter – vertical measurement Main bearings 1 to 4 parent bore diameter – horizontal measurement Main bearing 5 parent bore diameter – horizontal measurement Piston Dimensions Description Piston diameter – Class A Piston diameter – Class B Piston diameter – Class C Piston clearance in cylinder Piston ring end gaps – upper compression ring – lower compression ring – oil control ring 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 Main bearing journal end float Main bearing journals 1 to 4 diameter Main bearing journal 5 diameter Connecting rod bearing journal diameter Liters 8.89 8.55 mm 86.000-86.010 86.010-86.020 86.020-86.030 65.003-65.030 70.004-70.033 0.033-0.080 0.034-0.083 69.504-64.520 74.504-74.520 69.502-69.525 74.502-74.525 mm 85.94-85.95 85.95-85.96 85.96-85.97 0.05-0.07 0.25-0.50 0.50-0.75 0.25-0.50 mm 0.090-0.305 64.950-64.970 69.950-69.970 52.980-53.000

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-5 303-01B-5 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma SPECIFICATIONS Connecting Rod Dimensions Description Large end bore diameter Small end bore diameter Connecting rod bearing shell inner diameter – bearings installed Connecting rod bearing radial clearance Connecting rod bearing axial clearance Piston Pin Dimensions Description Piston pin length Piston pin diameter Piston pin slide clearance Camshaft Dimensions Description Camshaft end float Camshaft bearing journal diameter Camshaft bearing clearance – radial measurement Valve Dimensions Description Valve stem to valve guide clearance – intake valve Valve stem to valve guide clearance – exhaust valve Cylinder Head Dimensions Description Maximum distortion – measured longitudinally and diagonally Peak to valley height of mating surface Thickness of cylinder head gasket with piston protrusion of 0.430 - 0.520 mm Thickness of cylinder head gasket with piston protrusion of 0.521 - 0.570 mm Thickness of cylinder head gasket with piston protrusion of 0.571 - 0.620 mm Oil Pressure Specifications Description Minimum oil pressure at idle speed Minimum oil pressure at 2000 rpm mm 55.096-56.015 30.010-30.018 53.017-53.043 0.034-0.100 0.100-0.320 mm 66.700 30.000 0.002-0.012 mm 0.014-0.20 26.450 0.065 mm 0.045 0.055 mm 0.10 0.02 1.1 1.15(two hole/teeth) 1.2(three holes/teeth) bar 1.25 2.0

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-6 303-01B-6 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma SPECIFICATIONS Lubricants, Fluids, Sealers and Adhesives Item Ford Formula E SAE 5W-30 engine oil Sealer – oil pan, camshaft carrier and engine front cover Specification WSS-M2C913-c WSE-M4G323-A4

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-7 303-01B-7 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma DESCRIPTION AND OPERATION Engine œ Overview General ‡ The 2.2L Duratorq-TDCi (Puma) Diesel is available in three different power output versions: 88 kW (120 PS), 92 kW (125 PS) and 110 kW (150 PS). ‡ The 88 kW (120 PS) version has fixed vane turbocharger with a wastegate is used. ‡ The 92 kW (125 PS) version is available with fixed type and adjustable guide vane type also. ‡ The 110 kW (150 PS) version has a turbocharger with electrically adjustable guide vane geometry as well as fuel injectors with an increased flow rate. Features ‡ 4-cylinder turbodiesel 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 ‡ Exhaust camshaft driven by a timing belt ‡ Intake camshaft driven via a timing chain (driven by the exhaust camshaft) ‡ Valves actuated by roller cam followers with hydraulic tappets ‡ Variable-geometry turbocharger for optimum cylinder charging Fuel system ‡ Bosch common rail system with maximum fuel pump pressure of 1600 bar (also up to 1800 bar for a limited time) ‡ Fuel injectors with piezo technology ‡ Oil temperature sensor as an input variable for calculating the oil quality Engine management ‡ Bosch PCM (powertrain control module) EDC16CP39 ‡ Fuel metering valve, fuel pressure regulator and fuel pressure sensor for efficient regulation of the fuel pressure ‡ Actuator motor-controlled EGR (exhaust gas recirculation) valve Engine-emission control ‡ Meets EURO 5 ‡ Actuator motor-controlled EGR valve ‡ Intake manifold flap with position sensor ‡ Broadband Lambda probe for correcting the injection volume and for optimizing the EGR ‡ Coated DPF (diesel particulate filter) to minimize rust particle emissions Diagnosis ‡ Via the DLC (data link connector)with IDS (Integrated Diagnostic System) Specification Torque and power output:

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-8 303-01B-8 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma DESCRIPTION AND OPERATION 4 4 3 3 $ $ E99773 Item Description $ Torque (nm) % Power output(Kw) F Engine speed 1 Power output curve % % 1 1 2 2 & & Item Description 2 Engine speed curve 3 Torque during the overtorque function 4 Power output during the overtorque function

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B- 303-01B- - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma DESCRIPTION AND OPERATION Overview of the main engine components E131683 Item Description 1 Valve cover 2 Cylinder head - upper part 3 Cylinder head - lower part 1 2 3 4 5 Item Description 4 Cylinder block 5 Oil pan extension 6 Oil sump

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-10 303-01B-10 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma DESCRIPTION AND OPERATION Engine Engine -component location E131389

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-11 303-01B-11 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma DESCRIPTION AND OPERATION 3 4 5 1 2 E131390 1. Item Description 1 Oil sump 2 Turbocharger 3 vacuum pump 4 Valve cover 6 7 8 Item Description 5 Fuel injection rail 6 Intake manifold 7 Oil cooler 8 Coolant pump Fuel pump

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-12 303-01B-12 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma DESCRIPTION AND OPERATION E131401 2. Item Description 1 Engine code 2 Engine serial number

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-13 303-01B-13 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Camshafts(21 284 0) Special Tool(s) / General Equipment 100-010 Remover, O-Ring Seal E131853 303-1562 Timing Tool E131853 2 mm Punch 6 mm Drill Bit 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. NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Fuel Rail (303-04 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 (303-01 Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Removal and Installation). 3. Refer to: Timing Cover (303-01 Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Removal and Installation). 4. Refer to: Brake Vacuum Pump - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma (206-07 Power Brake Actuation, Removal and Installation). 5. Special Tool(s): 100-010 General Equipment: 2 mm Punch 100-010 100-010 2 2 1 1 3 3 E87423 6. General Equipment: 2 mm Punch E87424

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-14 303-01B-14 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 7. x2 x3 x3 x2 x2 E95464 8. x10 E75617 9. CAUTION: Remove the camshaft carrier bolts in the sequence shown. 1 7 15 19 21 23 13 5 3 17 11 9 12 10 4 18 2 8 16 20 22 24 14 6 E75958 Installation NOTE: Clean the mating faces of the camshaft carrier and the cylinder head. 1. ‡ Bolts 1 to 22 Torque: 23 Nm ‡ Bolts 23 to 25 Torque: 10 Nm 1 7 15 19 21 23 13 5 3 17 11 9 12 10 4 18 2 8 16 20 22 24 14 6 E75958 2. Torque: ‡ Stage 1: 10 Nm ‡ Stage 2: 30° x10 E75617 3. Install the Special Tool(s): 303-1562 303-1562 E138698

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-15 303-01B-15 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 4. NOTE: Make sure that the installation marks are aligned. General Equipment: 6 mm Drill Bit Torque: 33 Nm x3 x3 E95422 5. Remove the 6 mm drill bits. 6. 1. Torque: 15 Nm 2. Torque: 40 Nm 3. Torque: 40 Nm x2 1 x2 1 2 x2 3 E95442 7. NOTE: Make sure that a new component is installed. x2 E75760 8. Remove the Special Tool(s): 303-1562 303-1562 E138698 9. Rotate the engine two revolutions. 10.Install the Special Tool(s): 303-1562 303-1562 E138698

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-16 303-01B-16 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 11. Check the valve timing by inserting the drill bits. If the drill bits cannot be inserted repeat the timing steps. General Equipment: 6 mm Drill Bit E95424 12.Remove the 6 mm drill bits. 13.Remove the Special Tool(s): 303-1562 303-1562 E138698 14.Refer to: Brake Vacuum Pump - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma (206-07 Power Brake Actuation, Removal and Installation). 15.Refer to: Timing Cover (303-01 Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Removal and Installation). 16.Refer to: Valve Cover (303-01 Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Removal and Installation). 17.Refer to: Fuel Rail (303-04 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).

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-17 303-01B-17 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Crankshaft Front Seal(21 467 0) Special Tool(s) 303-1310 Holding Wrench, Crankshaft E87614 303-679A Remover/Installer, Engine Front Cover Inspection Plate E62024 1 x3 E131669 3. Special Tool(s): 303-679A 303-679A E131306 Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Cooling Fan Motor and Shroud (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, Removal and Installation). 2. 1. Do not completely loosen the crankshaft pulley bolts. Special Tool(s): 303-1310 X2 2 x3 303-1310

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-18 303-01B-18 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Installation 1. NOTE: Make sure that mounting face is clean and lubricated. E131312 2. CAUTION: A new crankshaft seal carrier is supplied with an alignment sleeve that must not be removed until the crankshaft seal if fully installed. Failure E133577 to follow this instruction may result in damage to the crankshaft. 303-679 E133587 3. E131367 4. NOTE: Initially hand tighten the fastners. Torque: ‡ Stage 1: 45 Nm ‡ Stage 2: 120° x3 X2 1 2 303-1310

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-19 303-01B-19 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 5. Refer to: Cooling Fan Motor and Shroud (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, Removal and Installation).

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-20 303-01B-20 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Crankshaft Rear Seal(21 468 4) Special Tool(s) 303-254 Locking Tool, Flywheel 21135 Materials Name Specification Silicone Sealant LB WSE-M4G323-A4 / 2U7J-M4G323-AA Removal NOTE: Removal steps in this procedure may contain installation details. Vehicles with automatic transmission 1. Refer to: Transmission - 2WD (307-01 Automatic Transmission/Transaxle - Vehicles With: 6-Speed Automatic Transaxle - 6R80, Removal). Refer to: Transmission - 4WD (307-01 Automatic Transmission/Transaxle - Vehicles With: 6-Speed Automatic Transaxle - 6R80, Removal). Vehicles with manual transmission 2. Refer to: Clutch Disc and Pressure Plate (308-01 Clutch - Vehicles With: 5-Speed Manual Transmission - MT75, Removal and Installation). Refer to: Clutch Disc and Pressure Plate (308-01 Clutch - Vehicles With: 6-Speed Manual Transmission - MT82, Removal and Installation). All vehicles 3. Special Tool(s): 303-254 x8 303-254 E131391

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-21 303-01B-21 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 4. x8 E131392 Installation All vehicles 1. E131398 2. NOTE: Install new crankshaft rear seal carrier with in five minutes after applying the recomended sealent. Material: Silicone Sealant LB (WSE-M4G323-A4 / 2U7J-M4G323-AA) sealant 3mm E131393 3. CAUTION: 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. 2 4 6 7 3 1 8 5 E131394

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-22 303-01B-22 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 4. NOTE: New crankshaft seal carriers are supplied with an alignment sleeve which must be removed after installation. Torque: 10 Nm 2 4 6 7 3 1 8 5 E131395 5. NOTE: Make sure that flywheel is in full contact with flywheel flange before installing the flywheel bolts. Hand tighten the bolts at this stage. x8 E131396 6. Torque: ‡ Stage 1: 15 Nm ‡ Stage 2: 30 Nm ‡ Stage 3: 75 Nm ‡ Stage 4: 45° 3 5 7 2 1 8 4 6 303-254 E131397 Vehicles with manual transmission 7. Refer to: Clutch Disc and Pressure Plate (308-01 Clutch - Vehicles With: 5-Speed Manual Transmission - MT75, Removal and Installation). Refer to: Clutch Disc and Pressure Plate (308-01 Clutch - Vehicles With: 6-Speed Manual Transmission - MT82, Removal and Installation). Vehicles with automatic transmission 8. Refer to: Transmission - 2WD (307-01 Automatic Transmission/Transaxle - Vehicles With: 6-Speed Automatic Transaxle - 6R80, Installation). Refer to: Transmission - 4WD (307-01 Automatic Transmission/Transaxle - Vehicles With: 6-Speed Automatic Transaxle - 6R80, Installation).

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-23 303-01B-23 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Cylinder Head(21 163 0) Special Tool(s) 205-069 Dial Indicator Gauge (Metric) 15046 205-070 Holding Fixture, Dial Indicator Gauge 15022A 303-432 Holding Fixture, Dial Indicator Gauge (Cylinder Liner Protrusion) 21183A Removal NOTE: Removal steps in this procedure may contain installation details. All vehicles 1. Refer to: Intake Manifold (303-01 Engine - 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. E135283 3. Torque: 3 Nm x4 E138566 Vehicles with fixed vane turbocharger 4. 1. Torque: 10 Nm 2. Torque: 12 Nm 2 x2 1 E135284

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-24 303-01B-24 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION All vehicles 5. Refer to: Exhaust Gas Recirculation (EGR) Valve - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma (303-08 Engine Emission Control - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 6. Refer to: Exhaust Manifold (303-01 Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Removal and Installation). 7. Refer to: Camshafts (303-01 Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Removal and Installation). 8. 2 x10 x8 3 1 E131726 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. E131727 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. E131633 3. NOTE: The largest measurement determines the choice of the cylinder head gasket. Special Tool(s): 303-432, 205-070, 205-069 205-070 303-432 205-069 E131634

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-25 303-01B-25 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 4. NOTE: Make sure that new component is installed. E131728 5. E139847 6. CAUTION: Make sure that new cylinder head bolts are installed. 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 40 Nm ‡ Stage 6: 11-18 20 Nm ‡ Stage 7: 1-10 180° ‡ Stage 8: 11-18 180° 15 5 11 1 13 10 3 17 7 16 12 6 2 8 4 14 18 E131729 7. To install, reverse the removal procedure.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-26 303-01B-26 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Exhaust Manifold(21 187 0) Removal NOTE: Removal steps in this procedure may contain installation details. 1. E131218 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, LHD 4WD/LHD RWD (303-04 Fuel Charging and Controls - Turbocharger, Removal and Installation). Refer to: Generator - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma (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, RHD 4WD/RHD 5:' (303-04 Fuel Charging and Controls - Turbocharger, Removal and Installation). 3. 1. Torque: 25 Nm 2. Torque: 23 Nm 3. Torque: 9 Nm 2 3 1 x4 x4 E130781 4. 1. Torque: 55 Nm 2. Torque: 40 Nm 3. Torque: 15 Nm 1 2 x6 x2 3 x3 E130782 5. x2 E130783 Installation NOTE: Install new exhaust manifold studs, bolts, nuts, gaskets and O-ring seals. 1. To install , reverse the removal procedure.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-27 303-01B-27 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Intake Manifold(21 183 0) Removal WARNINGS: 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. 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. 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. NOTE: Removal steps in this procedure may contain installation details. 1. E129579 2. E129766 3. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 4. E130889 5. Torque: 11 Nm x2 E133730

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-28 303-01B-28 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 6. Refer to: Exhaust Gas Recirculation (EGR) Valve - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma (303-08 Engine Emission Control - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 7. 2. Torque: 10 Nm 3. Torque: 15 Nm 2 x4 3 1 E133731 8. E133732 9. Torque: 25 Nm x9 E130825 Installation 1. NOTE: Inspect the intake manifold gaskets, Install new intake manifold gaskets if necessary. To install, reverse the removal procedure.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-29 303-01B-29 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Timing Cover(21 146 0) Special Tool(s) 303-428 Separator, Oil Pan 21179 303-682 Aligner, Engine Front Cover 303682 Materials Name Specification Silicone Sealant LB WSE-M4G323-A4 / 2U7J-M4G323-AA Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 2. Refer to: Cooling Fan Motor and Shroud (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, Removal and Installation). 3. Refer to: Generator - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma (414-02 Generator and Regulator, Removal and Installation). 4. Torque: 25 Nm x4 E135039 5. 1. Torque: 48 Nm 2. Torque: 23 Nm 2 x2 1 E131304

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-30 303-01B-30 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 6. Torque: 48 Nm x3 E134532 7. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 8. Torque: 30 Nm x4 E130132 9. NOTE: Remove front RH wheel only. Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation). 10. x8 E132537 11. CAUTION: Cap the power steering line to prevent fluid loss or dirt ingress. Torque: 7 Nm 3 2 1 E133691 12. x4 E133940

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-31 303-01B-31 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 13. 1. Torque: 20 Nm 2. Torque: 20 Nm 3. Torque: 18 Nm 1 2 3 E134533 14.Torque: 22 Nm E129991 15. E129992 16. 2. Torque: 23 Nm 4. Torque: 23 Nm 4 x2 3 2 1 E135034 17.Torque: 23 Nm 1 2 E134535

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-32 303-01B-32 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 18.Refer to: Crankshaft Front Seal (303-01 Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Removal and Installation). 19.Special Tool(s): 303-428 303-428 2 x20 1 x2 E135035 Installation 1. CAUTION: Install timing cover with in five minutes of applying the sealent. NOTE: Do not damage the mating surfaces. Material: Silicone Sealant LB (WSE-M4G323-A4 / 2U7J-M4G323-AA) sealant 3mm E131310

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-33 303-01B-33 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 2. 1. Special Tool(s): 303-682 Torque: 14 Nm 2. Torque: 10 Nm 1 x20 303-682 2 x2 E131309 3. To install, reverse the removal procedure.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-34 303-01B-34 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Oil Pan(21 154 0) Special Tool(s) 303-428 Separator, Oil Pan 21179 Materials Name Specification Silicone Sealant LB WSE-M4G323-A4 / 2U7J-M4G323-AA Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Engine Cooling System Health and Safety Precautions (100-00 General Information, Description and Operation). 2. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 3. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 4x4 4. Torque: 30 Nm x4 E130132 All vehicles 5. Torque: 30 Nm 1 x4 2 E128859 6. Torque: 90 Nm x4 x4 x3 E130951 4x4 7. Torque: 30 Nm

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-35 303-01B-35 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION x4 1 E133766 All vehicles 8. 1. Torque: 23 Nm 2. Torque: 150 Nm 3 x2 x2 2 E133875 9. NOTE: Be prepared to collect escaping fluid. NOTE: Inspect the oil pan drain plug seal for damage. Install a new drain plug and seal if required. 2 1

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-36 303-01B-36 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Drain the oil into a suitable container. Torque: 39 Nm 2 1 E130800 10.Special Tool(s): 303-428 303-428 3 x4 x12 2 1 E133877 4x4 11. Torque: 10 Nm E130953 12.Torque: 10 Nm E130954

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-37 303-01B-37 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 13. E130955 All vehicles 14. E133876 Installation 1. WARNING: Take extra care not to damage the mating faces. E133927 2. CAUTION: Install the oil pan within five minutes of applying the sealer. NOTE: Take extra care not to damage the mating faces. Material: Silicone Sealant LB (WSE-M4G323-A4 / 2U7J-M4G323-AA) sealant 3mm E130956

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-38 303-01B-38 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 3. Torque: ‡ Stage 1: 7 Nm ‡ Stage 2: 14 Nm 6 1 12 3 15 8 16 11 13 5 4 2 14 10 7 E133897 4. To install, reverse the removal procedure. 5. Fill the engine with clean engine oil. Refer to: Specifications (303-01 Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Specifications).

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-39 303-01B-39 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Oil Pump(21 714 0) Special Tool(s) 303-705 Aligner, Oil Pump 303705 Removal NOTE: Removal steps in this procedure may contain installation details. All vehicles 1. Refer to: Oil Pan (303-01 Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Removal and Installation). 4x2 2. x2 E133868 All vehicles 3. WARNING: Be prepared to collect escaping fluids. 2 1 E131546 4. NOTE: The profile of the special tool must be in contact with the oil pump sprocket. Install the Special Tool(s): 303-705 303-705 E133870

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-40 303-01B-40 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 5. NOTE: Do not completely loosen the bolts at this stage. Special Tool(s): 303-705 x4 E131548 6. Special Tool(s): 303-705 303-205 1 x4 3 2 E133869 Installation 1. NOTE: The profile of the special tool must be in contact with the oil pump sprocket. Special Tool(s): 303-705 303-705 1 2 E133871 2. NOTE: Hand tighten the bolts at this stage. 303-705 x4 E133872

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-41 303-01B-41 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 3. 1. Torque: 10 Nm 3 2 x2 1 x4 E139413 4. Torque: 13 Nm 1 2 E131552 4x2 5. Torque: 10 Nm x2 E133868 All vehicles 6. Refer to: Oil Pan (303-01 Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Removal and Installation).

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-42 303-01B-42 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Valves Special Tool(s) 303-060 Compressor, Valve Spring 21024 303-060-05 Adapter for 303-060 2102405 Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Cylinder Head (303-01 Engine - 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. NOTE: Position a socket on the valve spring seat and gently strike it with a hammer. ELE0015706 Special Tool(s) 303-060-07 Adapter for 303-060 303-362 Installer, Valve Stem Collets 21156 3. Special Tool(s): 303-060, 303-060-05, 303-060-07, 303-362 303-060 303-060-05 303-362 303-060-07 E131794

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-43 303-01B-43 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 4. E139000 Installation 1. To install, reverse the removal procedure.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-44 303-01B-44 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Valve Cover(21 141 0) Removal NOTE: Removal steps in this procedure may contain installation details. All vehicles 1. E130901 Vehicles with fixed vane turbocharger 2. E134581 3. 1. Torque: 10 Nm 2. Torque: 23 Nm 1 x2 2 E133773 All vehicles 4. Refer to: Fuel Injectors (303-04 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). 5. 1. Torque: ‡ Stage 1: 5 Nm ‡ Stage 2: 35 Nm 2. Torque: 10 Nm x3 2 1 1 E133633 6. E134574

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-45 303-01B-45 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 7. Torque: 10 Nm x2 x4 x5 E133634 8. E134582 Installation NOTE: Install a new valve cover gasket as necessary. 1. To install, reverse the removal procedure.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-46 303-01B-46 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Valve Stem Seals(21 238 0) Special Tool(s) 303-390 Pliers, Valve Stem Seal 21165 Removal 1. Refer to: Valve Springs (303-01 Engine - 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. Special Tool(s): 303-390 303-390 E131778 Installation 1. To install, reverse the removal procedure.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-47 303-01B-47 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Valve Springs Special Tool(s) 303-060 Compressor, Valve Spring 21024 303-060-05 Adapter for 303-060 2102405 Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Valve Cover (303-01 Engine - 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. x10 E131785 3. Position the appropriate piston at top dead center (TDC). Special Tool(s) 303-060-07 Adapter for 303-060 2102407 303-362 Installer, Valve Stem Collets 21156 4. Using the special tools, remove the valve collets. Special Tool(s): 303-060, 303-060-05, 303-060-07, 303-362 303-060 303-060-07 303-362 303-060-05 E131786

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-48 303-01B-48 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Installation 1. 303-060 303-060-07 303-362 303-060-05 E131786 2. Torque: ‡ Stage 1: 10 Nm ‡ Stage 2: 30° x10 E131785 3. Refer to: Valve Cover (303-01 Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Removal and Installation).

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-49 303-01B-49 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL Engine – Vehicles With: 5-Speed Manual Transmission - MT75(21 132 0; 21 132 6; 21 132 7) Removal Special Tool(s) / General Equipment 303-122 Lifting Bracket, Engine 21068A Transmission Jack 1. Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation). 2. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 3. Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma (303-03 Engine Cooling - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures). 4. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures). 5. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 6. 1 x4 2 E128859

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-50 303-01B-50 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 7. E129579 8. x9 E131903 9. x7 E131904 10. x4 E131940 11. Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation). 12. x2 E134162 13.On both sides. E128788 14.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-51 303-01B-51 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL x7 E133552 15. E135084 x2 x6 16. E135083

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-52 303-01B-52 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 17.Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation). 18.Refer to: Battery TUay (414-01 Battery, Mounting and Cables, Removal and Installation). 19.Refer to: Powertrain Control Module (PCM) (303-14 Electronic Engine Controls - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). Refer to: Powertrain Control Module (PCM) (303-14 Electronic Engine Controls - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 20. x4 E139349 21. x2 E139350 22. x2 E135085 23. 2 1 E134703 24. E132020

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-53 303-01B-53 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 25.Refer to: Cooling Fan Motor and Shroud (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, Removal and Installation). 26.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, Removal and Installation). 27.Refer to: Condenser - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma (412-01 Climate Control, Removal and Installation). 28. E135125 E135124 29.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 (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 30. E131212 31.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-54 303-01B-54 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 32.Refer to: Air Cleaner - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma (303-12 Intake Air Distribution and Filtering - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 33.NOTE: Make sure that all openings are sealed. E135087 34. CAUTION: Cap the power steering line to prevent fluid loss or dirt ingress. NOTE: The washers can be reused unless damaged. 2 1 x2 3 E135088 35. E134704 36. E135092 37. 1 2 x2 E134777

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-55 303-01B-55 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 38.Refer to: Catalytic Converter (309-00 Exhaust System - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 39. E134705 40. 1 2 E135089 41. E132699 42. E134708 43. E134707 44. WARNING: Make sure that transmission assembly is on wooden blocks and secured with suitable retaining straps. CAUTION: Do not tilt the transmission.This may cause damage to the pilot bearing.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-56 303-01B-56 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL Tie and support the transmission to the chassie with a suitable strap. General Equipment: Transmission Jack E128845 45. x3 E132702 46. x2 x4 E132701 47.On both sides. E132028 48.Special Tool(s): 303-122 303-122 E68699

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-57 303-01B-57 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 49. E135090 50. x3 2 1 E132029

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-58 303-01B-58 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL Engine – Vehicles With: 6-Speed Manual Transmission - MT82(21 132 0; 21 132 6; 21 132 7) Removal Special Tool(s) / General Equipment 303-122 Lifting Bracket, Engine 21068A Transmission Jack 1. Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation). 2. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 3. Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma (303-03 Engine Cooling - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures). 4. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures). 5. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 6. 1 x4 2 E128859

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-59 303-01B-59 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 7. E129579 8. x9 E131903 9. x7 E131904 10. x4 E131940 11. Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation). 12. x2 E134162 13.On both sides. E128788 14.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-60 303-01B-60 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL x7 E133552 15. E135084 x2 x6 16. E135083

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-61 303-01B-61 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 17.Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation). 18.Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation). 19.Refer to: Powertrain Control Module (PCM) (303-14 Electronic Engine Controls - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). Refer to: Powertrain Control Module (PCM) (303-14 Electronic Engine Controls - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 20. x4 E139349 21. x2 E139350 22. x2 E135085 23. 2 1 E134703 24. E132020

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-62 303-01B-62 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 25.Refer to: Cooling Fan Motor and Shroud (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, Removal and Installation). 26.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, Removal and Installation). 27.Refer to: Condenser - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma (412-01 Climate Control, Removal and Installation). 28. E135125 E135086 29.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 (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 30. E131212 31.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-63 303-01B-63 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 32.Refer to: Air Cleaner - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma (303-12 Intake Air Distribution and Filtering - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 33.NOTE: Make sure that all openings are sealed. E135087 34. CAUTION: Cap the power steering line to prevent fluid loss or dirt ingress. NOTE: The washers can be reused unless damaged. 2 1 x2 3 E135088 35. E134704 36. E135092 37. 1 2 x2 E134777

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-64 303-01B-64 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 38.Refer to: Catalytic Converter (309-00 Exhaust System - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 39. E134705 40. 1 2 E135089 41. E132699 42. E134708 43. E134707 44. WARNING: Make sure that transmission assembly is on wooden blocks and secured with suitable retaining straps. CAUTION: Do not tilt the transmission.This may cause damage to the pilot bearing.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-65 303-01B-65 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL Tie and support the transmission to the chassis with a suitable strap. General Equipment: Transmission Jack E128845 45. x3 E132702 46. x2 x4 E132701 47.On both sides. E132028 48.Special Tool(s): 303-122 303-122 E68699

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-66 303-01B-66 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 49. E135090 50. x3 2 1 E132029

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-67 303-01B-67 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL Engine – Vehicles With: 6-Speed Automatic Transaxle - 6R80(21 132 0; 21 132 6; 21 132 7) Removal Special Tool(s) / General Equipment 303-122 Lifting Bracket, Engine 21068A Transmission Jack 1. Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation). 2. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 3. Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma (303-03 Engine Cooling - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures). 4. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures). 5. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 6. 1 x4 2 E128859

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-68 303-01B-68 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 7. E129579 8. x9 E131903 9. x7 E131904 10. x4 E131940 11. Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation). 12. x2 E134162 13.On both sides. E128788 14.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-69 303-01B-69 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL x7 E133552 15. E135084 x2 x6 16. E135083

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-70 303-01B-70 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 17.Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation). 18.Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation). 19.Refer to: Powertrain Control Module (PCM) (303-14 Electronic Engine Controls - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 20. x4 E139349 21. x2 E139350 22. x2 E135085 23. 2 1 E134703 24. E132020

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-71 303-01B-71 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 25.Refer to: Cooling Fan Motor and Shroud (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, Removal and Installation). 26.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, Removal and Installation). 27.Refer to: Condenser - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma (412-01 Climate Control, Removal and Installation). 28. E135125 E135086 29.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 (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 30.Refer to: Transmission Fluid Cooler (307-02 Transmission/Transaxle Cooling, Removal and Installation). 31. E131212 32.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-72 303-01B-72 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 33.Refer to: Air Cleaner - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma (303-12 Intake Air Distribution and Filtering - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 34.NOTE: Make sure that all openings are sealed. E135087 35. CAUTION: Cap the power steering line to prevent fluid loss or dirt ingress. NOTE: The washers can be reused unless damaged. 2 1 3 E135088 36. E134704 37. E135092 38. 1 2 x2 E134777

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-73 303-01B-73 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 39.Refer to: Catalytic Converter (309-00 Exhaust System - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 40. E134705 41. 1 2 E135089 42. E132699 43. E134708 44. E134707 45. WARNING: Make sure that transmission assembly is on wooden blocks and secured with suitable retaining straps. CAUTION: Do not tilt the transmission. This may cause damage to the pilot bearing.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-74 303-01B-74 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL Tie and support the transmission to the chassis with a suitable strap. General Equipment: Transmission Jack E128845 46. x2 x3 E135451 47. x2 E135453 48.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-75 303-01B-75 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 2 E135454 49. x2 E135452 303-1310 60 1 x6 2 50.On both sides. E132028 51.Special Tool(s): 303-122 303-122 E68699

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-76 303-01B-76 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 52. E135090 53. x3 2 1 E132029

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-77 303-01B-77 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL Engine Accessories(21 139 4) Removal Special Tool(s) / General Equipment 303-122 Lifting Bracket, Engine 21068A 303-1310 Holding Wrench, Crankshaft E87614 303-1317 Locking Tool, Fuel Injection Pump Sprocket E75376 303-249 Remover, Crankshaft Timing Pulley 21132 303-254 Locking Tool, Flywheel 21135 303-435 Mounting Stand 21187 Special Tool(s) / General Equipment 303-435-06 Mounting Bracket for 303-435 21031B 303-435-11B Mounting Plate for 303-435-06 E68386 303-679 Remover/Installer, Engine Front Cover Inspection Plate 303-679A Remover/Installer, Engine Front Cover Inspection Plate E62024 1/2 Inch Square Drive Breaker Bar Dowel with a Diameter of 6 mm 1. Install the Special Tool(s): 303-122 303-122 E68699

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-78 303-01B-78 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 2. E138419 3. x2 E138420 4. E138421 5. 1 x2 2 E134641 6. 1 2 E138440 7. Install the Special Tool(s): 303-435-11B 303-435-11B E87393

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-79 303-01B-79 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 8. Install the Special Tool(s): 303-435, 303-435-06 303-435-06 303-435 E87394 1 E131376 9. Remove the Special Tool(s): 303-122 303-122 E68699 10.General Equipment: 1/2 Inch Square Drive Breaker Bar General Equipment: Dowel with a Diameter of 6 mm 2

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-80 303-01B-80 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 11. CAUTION: Take extra care not to damage the wiring harnesses. 2 1 3 5 x3 4 E131383 12. x4 E138459 13. E138429 14. x2 E138430 15. x4 E138452

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-81 303-01B-81 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 16. 1 2 x6 x2 3 x3 E130782 17.NOTE: The gasket is to be reused unless damaged. NOTE: The studs are to be reused unless damaged. x2 E130783 18. E138422 19. E135272 20. E135273 21.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-82 303-01B-82 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL E138423 22. 2 x4 3 1 E133731 23. CAUTION: Make sure that all openings are sealed. Use new blanking caps. E138426

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-83 303-01B-83 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 24. x3 E138424 E138534 25.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-84 303-01B-84 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 26. x2 E138425 27. x2 E138436 28. x3 E87416 29.NOTE: Do not loosen the bolts more than 2 turns. 6 1 4 X2 3 2 5 E129960 30.Special Tool(s): 303-254 303-254 x8 E138465 31. x8 E131392

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-85 303-01B-85 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 32. x9 E138427 33. x4 x4 E129581 34.CAUTIONS: 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. 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. Make sure that all openings are sealed. Use new blanking caps. E129688 35. x2 E129705 36. x2 E138483 37. E129584

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-86 303-01B-86 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 38. x4 E139503 39. E138434 40.Special Tool(s): 303-679 303-679 E129923 41. E97216 42.Install the Special Tool(s): 303-1317 303-1317 303-1317 E97221 43. E129689

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-87 303-01B-87 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 44.Special Tool(s): 303-1317, 303-249 303-1317 303-249 E97222 45. E138700 46. 2 x2 1 E131304 47. x2 E138793 48. x6 E138791 49. x8 E138785

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-88 303-01B-88 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL 50. x3 E134532 1 x3 E131669 52.Special Tool(s): 303-679A 303-679A E131306 51.Special Tool(s): 303-1310 X2 2 x3 303-1310

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-89 303-01B-89 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma DISASSEMBLY Engine(21 134 8) Disassembly Special Tool(s) / General Equipment 100-010 Remover, O-Ring Seal 17063 303-1317 Locking Tool, Fuel Injection Pump Sprocket E75376 303-249 Remover, Crankshaft Timing Pulley 21132 303-428 Separator, Oil Pan 21179 303-679 Remover/Installer, Engine Front Cover Inspection Plate 303679 2 mm Punch 1. Torque: 25 Nm E138700 2. Remove the Special Tool(s): 303-249 303-1317 303-1317 303-249 303-249 E97222 3. NOTE: Make sure that a new component is installed. Torque: 45 Nm E138701

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-90 303-01B-90 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma DISASSEMBLY 4. Torque: 22 Nm E129689 5. Remove the Special Tool(s): 303-1317 303-1317 E97225 6. Remove the Special Tool(s): 303-679 303-679 E73839 7. x20 x2 E75620 8. Special Tool(s): 303-428 303-428 E87411 9. E94201

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-91 303-01B-91 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma DISASSEMBLY 10.Special Tool(s): 100-010 General Equipment: 2 mm Punch 100-010 2 1 3 E87812 11. Remove and discard the timing chain tensioner. General Equipment: 2 mm Punch E87813 12. x3 x5 x4 x2 E138435 13. E134582 14. x2 x3 x3 x2 x2 E95464 15. x10 E75617

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-92 303-01B-92 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma DISASSEMBLY 16. 7 7 15 19 21 23 13 5 3 17 11 9 12 10 4 18 2 8 16 20 22 24 14 6 E75958 17. 3 15 7 17 5 13 1 11 9 12 10 4 16 8 18 6 14 2 E75952 18. WARNING: Be prepared to collect escaping fluid. 2 1 E130800 19.Special Tool(s): 303-428 x14 303-428 x2 E139685 20. E76144 21. x6 E138437

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-93 303-01B-93 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma DISASSEMBLY 22. E138703 23. E87419 24.NOTE: Note the position of each component before removal. E73644 25.NOTE: Note the position of each component before removal. E77286 26. E76386 27.NOTE: Note the position of each component before removal. 5 7 3 1 10 4 2 6 8 E73645

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-94 303-01B-94 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma DISASSEMBLY 28.NOTE: Note the position of each component before removal. E77266 29.NOTE: Note the position of each component before removal. x4 x4 E138535

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-95 303-01B-95 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Cylinder Head(21 165 6) Disassembly 1. For additional information, refer to: 9DOYHV (303-01 Engine - 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. Torque : 13 Nm x4 E139759 3. Torque : 23 Nm x2 E138008 Assembly 1. To assemble, reverse the disassembly procedure.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-96 303-01B-96 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma ASSEMBLY Engine(21 134 8) Assembly Special Tool(s) / General Equipment 205-044 Holding Fixture, Dial Indicator Gauge 15008 205-069 Dial Indicator Gauge (Metric) 15046 205-070 Holding Fixture, Dial Indicator Gauge 15022A 303-1562 Timing Tool E131853 303-254 Locking Tool, Flywheel 21135 303-391 Setting Gauge, Crankshaft 21166 Special Tool(s) / General Equipment 303-428 Separator, Oil Pan 21179 303-432 Holding Fixture, Dial Indicator Gauge (Cylinder Liner Protrusion) 21183 303-682 Aligner, Engine Front Cover 303682 6 mm Drill Bit Piston Ring Compressor Round-Ended Steel Rule Materials Name Specification Engine Oil - 5W-30 WSS-M2C913-C Silicone Sealant LB WSE-M4G323-A4 / 2U7J-M4G323-AA

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-97 303-01B-97 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma ASSEMBLY 1. NOTE: Make sure that these components are installed to the noted removal position. Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil Torque: 10 Nm 3 1 x4 x4 2 E139686 2. NOTE: Make sure that these components are installed to the noted removal position. Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil E85103 3. 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: 15 Nm ‡ Stage 2: 20 Nm ‡ Stage 3: 35 Nm ‡ Stage 4: 80 Nm ‡ Stage 5: 90° 5 3 1 7 10 4 2 6 8 E73645 4. General Equipment: Piston Ring Compressor Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil x4 x4 E87405

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-98 303-01B-98 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma ASSEMBLY 5. NOTE: Make sure that these components are installed to the noted removal position. Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil E85147 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: 25 Nm ‡ Stage 2: 60 Nm ‡ Stage 3: 90° E73644 7. E87419 8. NOTE: Only tighten the bolts finger tight at this stage. E138703 9. 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. Special Tool(s): 303-432 303-432 E76169

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B- 303-01B- - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma ASSEMBLY 10.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. General Equipment: Round-Ended Steel Rule E76155 11. Torque: 23 Nm 19 12 8 11 22 7 3 2 6 14 18 15 9 4 1 5 10 16 17 13 20 21 E73643 12.NOTE: Only tighten the bolts finger tight at this stage. x6 E138437 13.Take a reference measurement from the front face of the crankshaft sprocket. Special Tool(s): 205-044, 205-069 205-069 205-044 E87421 14.Take measurements at two different points on the oil pump sprocket and align the oil pump sprocket. Special Tool(s): 205-044, 205-069 205-044 205-069 E87422 15.Torque: 10 Nm x6 E138437

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-100 303-01B-100 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma ASSEMBLY 16. E76144 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. E58864 18. E131398 19.NOTE: Install new crankshaft rear seal carrier with in five minutes after applying the recomended sealent. Material: Silicone Sealant LB (WSE-M4G323-A4 / 2U7J-M4G323-AA) sealant 3mm E131393 20. CAUTION: 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.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-101 303-01B-101 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma ASSEMBLY NOTE: Initially hand tighten the fasteners. 2 4 6 7 3 1 8 5 E131394 21.NOTE: New crankshaft seal carriers are supplied with an alignment sleeve which must be removed after installation. Torque: 20 Nm 2 4 6 7 3 1 8 5 E131395 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. x8 E131396 23. CAUTION: Make sure that the flywheel is in full contact with the crankshaft flange before installing the flywheel bolts. Special Tool(s): 303-254 Torque: ‡ Stage 1: 15 Nm ‡ Stage 2: 30 Nm ‡ Stage 3: 75 Nm ‡ Stage 4: 45° 3 5 7 2 1 8 6 4 303-254 E131397

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-102 303-01B-102 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma ASSEMBLY 24.Special Tool(s): 205-069, 205-070 205-070 205-069 TIE0034799 25.NOTE: Do not fully tighten the crankshaft position sensor bracket retaining bolts at this stage. x2 x2 E87418 26.NOTE: After installation do not move the special tool. Special Tool(s): 303-391 303-391 TIE0034801 27.Rotate the crankshaft until piston No. one is approximately 10 mm before top dead center (TDC). Special Tool(s): 205-069, 205-070 28.Zero the dial indicator gauge. 205-070 205-069 TIE0034799 29.Mark the position on the flywheel primary mass. Special Tool(s): 303-391 303-391 TIE0034802 30.NOTE: Rotate the crankshaft counterclockwise. 1. Rotate the crankshaft until the piston No. one achieves zero on the dial indicator gauge. 2. Mark the position on the flywheel primary mass. Special Tool(s): 303-391 31.Repeat the previous steps to make sure that the marking is correct. 303-391 TIE0034803 32.NOTE: The middle of the markings is TDC.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-103 303-01B-103 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma ASSEMBLY Measure the distance between the two marks. TIE0034804 33.Divide the amount by two and mark the position TDC on the flywheel primary mass. 34.Measure the circumference of the flywheel primary mass. TIE00348009 35.Multiply the circumference by 0.1388 and mark the calculated amount on the flywheel primary mass by measuring from TDC counterclockwise. 36. 1. First mark. 2. Second mark. 3. Determined TDC. 4. Determined 50 degrees before top dead center (BTDC). 1 3 2 4 TIE0034805 37. CAUTION: 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 crankshaft in the normal direction of rotation to the mark of the calculated 50 degrees BTDC. NOTE: Make sure that the special tool is fully located in the flywheel so that the engine cannot be rotated in either direction. Special Tool(s): 303-1562 303-1562 E138698 38.Remove the Special Tool(s): 303-1562 Torque: 25 Nm 303-1562 x2 E138699 39. 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

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-104 303-01B-104 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma ASSEMBLY paths. Use a plastic scraping tool to remove all traces of the head gasket. E131727 40.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. E131633 41.NOTE: The largest measurement determines the choice of the cylinder head gasket. ‡ Using the special tools, measure the piston protrusion. Special Tool(s): 205-070, 205-069, 303-432 205-070 303-432 205-069 E131634 42.Determine the cylinder head gasket. Refer to: Specifications (303-01 Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Specifications). 43.NOTE: Make sure that a new component is installed. E76153

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-105 303-01B-105 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma ASSEMBLY 44. E138999 45.NOTE: Install all the bolts finger tight before final tightening. Torque: ‡ Bolts 1 to 10 10 Nm ‡ Bolts 11 to 18 5 Nm ‡ Bolts 1 to 10 20 Nm ‡ Bolts 11 to 18 10 Nm ‡ Bolts 1 to 10 40 Nm ‡ Bolts 11 to 18 20 Nm ‡ Bolts 1 to 10 180° ‡ Bolts 11 to 18 180° 2 15 11 1 13 10 3 17 7 16 12 6 2 4 8 14 18 E131729 46.Material: Silicone Sealant LB (WSE-M4G323-A4 / 2U7J-M4G323-AA) sealant E76154 47.Torque: ‡ Bolts 1 to 22 ‡ Stage 1: 5 Nm ‡ Stage 2: 23 Nm ‡ Bolts 23 to 24 ‡ Stage 1: 5 Nm ‡ Stage 2: 10 Nm 24 18 10 6 4 2 12 20 22 8 14 16 13 15 21 7 23 17 9 5 3 1 11 19 E75949 48.Torque: ‡ Stage 1: 10 Nm ‡ Stage 2: 30° x10 E75617

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-106 303-01B-106 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma ASSEMBLY 49.Special Tool(s): 303-1562 303-1562 E138698 50.NOTE: Make sure that the installation marks are aligned. General Equipment: 6 mm Drill Bit Torque: 33 Nm x3 x3 E95422 51.Remove the 6 mm drill bits. 52. CAUTION: Make sure that new bolts are installed. 1. Torque: 15 Nm 2. Torque: 40 Nm x2 1 x2 1 2 x2 3 E95442 53.NOTE: Make sure that a new component is installed. Torque: 15 Nm x2 E75760 54.Remove the Special Tool(s): 303-1562 303-1562 E138698

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-107 303-01B-107 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma ASSEMBLY 55.Rotate the engine two revolutions. 56.Special Tool(s): 303-1562 303-1562 E138698 57.Check the position of the timing marks and correct if necessary. 58.Remove the 6 mm drill bits. E95424 59.Remove the Special Tool(s): 303-1562 303-1562 E138698 60. E134582 61.Torque: 10 Nm x3 x5 x4 x2 E138435 62.NOTE: Make sure that a new component is installed. E94201 63.NOTE: The component must be installed within 5 minutes of applying the sealant.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-108 303-01B-108 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma ASSEMBLY NOTE: Make sure that a new component is installed. Material: Silicone Sealant LB (WSE-M4G323-A4 / 2U7J-M4G323-AA) sealant 3mm E131310 64.Special Tool(s): 303-682 Torque: ‡ 1 10 Nm ‡ 2 11 Nm 303-682 1 2 x2 x20 E87427 65.NOTE: Do not damage the mating faces. Special Tool(s): 303-428 303-428 E133924 66. CAUTION: Install the oil pan within five minutes of applying the sealer. NOTE: Do not damage the mating faces. Material: Silicone Sealant LB (WSE-M4G323-A4 / 2U7J-M4G323-AA) sealant 3mm E130956

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-109 303-01B-109 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma ASSEMBLY 67.Torque: ‡ Stage 1: 7 Nm ‡ Stage 2: 14 Nm 6 1 12 3 15 8 16 11 13 5 4 2 14 10 7 E133897

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-110 303-01B-110 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION Engine – Vehicles With: 5-Speed Manual Transmission - MT75(21 132 0; 21 132 6; 21 132 7) Installation Special Tool(s) 303-122 Lifting Bracket, Engine 21068A 1. Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation). 2. Special Tool(s): 303-122 303-122 E68699 3. E135093 4. NOTE: Hand tighten the nut at this stage. E132028 5. NOTE: Hand tighten the nut at this stage. x3 2 1 E132029 6. NOTE: Hand tighten the nut at this stage. E135094

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-111 303-01B-111 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 7. Initially hand tighten the fasteners. Torque: 48 Nm x2 x4 E132701 8. Initially hand tighten the fasteners. Torque: 48 Nm x3 E132702 9. Torque: 80 Nm E132028 10. 1. Torque: 48 Nm 2. Torque: 48 Nm x3 2 1 E132029 11. Torque: 80 Nm E135094 12.Remove the Special Tool(s): 303-122 303-122 E68699

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-112 303-01B-112 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 13.Torque: 13 Nm E135107 14. E134708 15.Torque: 22 Nm E132699 16. E134705 17. 2. Torque: 10 Nm 1 2 E135089

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-113 303-01B-113 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 18.Refer to: Catalytic Converter (309-00 Exhaust System - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 19. 1. Torque: 47 Nm 2. Torque: 22 Nm 1 2 x2 E134777 20. E135092 21. E134704 22.NOTE: The washers can be reused unless damaged. 3. Torque: 35 Nm 2 3 1 E135108 23. E135087

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-114 303-01B-114 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 24.Torque: 22 Nm E135109 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 (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 26. E135125 27.Refer to: Condenser - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma (412-01 Climate Control, Removal and Installation). 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, Removal and Installation). 29.Refer to: Cooling Fan Motor and Shroud (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, Removal and Installation). 30.Refer to: Air Cleaner - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma (303-12 Intake Air Distribution and Filtering - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 31.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-115 303-01B-115 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION E135124 32. E135110 33.Torque: 10 Nm x2 E135085 34.Torque: 18 Nm x2 E139350 35.Torque: 5 Nm E135084

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-116 303-01B-116 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 36. E135104 37. x4 E139349 38.Refer to: Powertrain Control Module (PCM) (303-14 Electronic Engine Controls - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). Refer to: Powertrain Control Module (PCM) (303-14 Electronic Engine Controls - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 39.Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation). 40.Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation). 41.Torque: 10 Nm

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-117 303-01B-117 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION x7 E133552 42.On both sides. E135112 43.Torque: 10 Nm x2 E134162 x2 x6 44.Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation). 45.Torque: 25 Nm x4 E131940 46. x7 E131904

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-118 303-01B-118 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 47. x9 E131903 48. E129579 49.Torque: 30 Nm x4 E135111 50.Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures). 51.Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma (303-03 Engine Cooling - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures). 52.Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-119 303-01B-119 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION Engine – Vehicles With: 6-Speed Manual Transmission - MT82(21 132 0; 21 132 6; 21 132 7) Installation Special Tool(s) 303-122 Lifting Bracket, Engine 21068A 1. Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation). 2. Special Tool(s): 303-122 303-122 E68699 3. E135093 4. NOTE: Hand tighten the nut at this stage. E132028 5. NOTE: Hand tighten the nut at this stage. x3 2 1 E132029 6. NOTE: Hand tighten the nut at this stage. E135094

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-120 303-01B-120 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 7. Initially hand tighten the fasteners. Torque: 48 Nm x2 x4 E132701 8. Initially hand tighten the fasteners. Torque: 48 Nm x3 E132702 9. Torque: 80 Nm E132028 10. 1. Torque: 48 Nm 2. Torque: 48 Nm x3 2 1 E132029 11. Torque: 80 Nm E135094 12.Remove the Special Tool(s): 303-122 303-122 E68699

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-121 303-01B-121 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 13.Torque: 13 Nm E135107 14. E134708 15.Torque: 22 Nm E132699 16. E134705 17. 2. Torque: 10 Nm 1 2 E135089

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-122 303-01B-122 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 18.Refer to: Catalytic Converter (309-00 Exhaust System - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 19. 1. Torque: 47 Nm 2. Torque: 22 Nm 1 2 x2 E134777 20. E135092 21. E134704 22.NOTE: The washers can be reused unless damaged. 3. Torque: 35 Nm 2 3 1 E135108 23. E135087

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-123 303-01B-123 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 24.Torque: 22 Nm E135109 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 (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 26. E135125 27.Refer to: Condenser - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma (412-01 Climate Control, Removal and Installation). 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, Removal and Installation). 29.Refer to: Cooling Fan Motor and Shroud (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, Removal and Installation). 30.Refer to: Air Cleaner - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma (303-12 Intake Air Distribution and Filtering - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 31.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-124 303-01B-124 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION E135086 32. E135110 33.Torque: 10 Nm x2 E135085 34.Torque: 18 Nm x2 E139350 35.Torque: 5 Nm E135084

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-125 303-01B-125 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 36. E135104 37. x4 E139349 38.Refer to: Powertrain Control Module (PCM) (303-14 Electronic Engine Controls - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). Refer to: Powertrain Control Module (PCM) (303-14 Electronic Engine Controls - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 39.Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation). 40.Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation). 41.Torque: 10 Nm

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-126 303-01B-126 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION x7 E133552 42.On both sides. E135112 43.Torque: 10 Nm x2 E134162 x2 x6 44.Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation). 45.Torque: 25 Nm x4 E131940 46. x7 E131904

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-127 303-01B-127 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 47. x9 E131903 48. E129579 49.Torque: 30 Nm x4 E135111 50.Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures). 51.Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma (303-03 Engine Cooling - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures). 52.Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-128 303-01B-128 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION Engine – Vehicles With: 6-Speed Automatic Transaxle - 6R80(21 132 0; 21 132 6; 21 132 7) Installation Special Tool(s) 303-122 Lifting Bracket, Engine 21068A 1. Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation). 2. Special Tool(s): 303-122 303-122 E68699 3. E135093 4. NOTE: Hand tighten the nut at this stage. E132028 5. NOTE: Hand tighten the nut at this stage. x3 2 1 E132029 6. NOTE: Hand tighten the nut at this stage. E135094

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-129 303-01B-129 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 7. Initially hand tighten the fasteners. Torque: 48 Nm x2 x3 E135451 8. Initially hand tighten the fasteners. Torque: 48 Nm x2 E135452 9. Torque: 80 Nm E135094 10. 1. Torque: 48 Nm 2. Torque: 48 Nm 2 1 E132029 11. Torque: 80 Nm E132028 12.Remove the Special Tool(s): 303-122 303-122 E68699

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-130 303-01B-130 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 13.Torque: 13 Nm E135107 2 E135454 14.Torque: 40 Nm 303-1310 60 1 x6 2

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-131 303-01B-131 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 15.Torque: 22 Nm x2 E135453 16. E134708 17.Torque: 22 Nm E132699 18. E134705 19. 2. Torque: 10 Nm 1 2 E135089 20.Refer to: Catalytic Converter (309-00 Exhaust System - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 21. 1. Torque: 47 Nm 2. Torque: 22 Nm 1 2 x2 E134777

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-132 303-01B-132 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 22. E135092 23. E134704 24.NOTE: The washers can be reused unless damaged. 3. Torque: 35 Nm 2 3 1 E135108 25. E135087

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-133 303-01B-133 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 26.Torque: 22 Nm E135109 27.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 (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 28. E135125 E135086 29.Refer to: Transmission Fluid Cooler (307-02 Transmission/Transaxle Cooling, Removal and Installation). 30.Refer to: Condenser - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma (412-01 Climate Control, Removal and Installation). 31.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, Removal and Installation). 32.Refer to: Cooling Fan Motor and Shroud (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, Removal and Installation). 33.Refer to: Air Cleaner - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma (303-12 Intake Air Distribution and Filtering - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 34.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-134 303-01B-134 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 35. E135110 36.Torque: 10 Nm x2 E135085 37.Torque: 18 Nm x2 E139350 38.Torque: 5 Nm E135084 39. E135104

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-135 303-01B-135 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 40. x4 E139349 x7 E133552 41.Refer to: Powertrain Control Module (PCM) (303-14 Electronic Engine Controls - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 42.Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation). 43.Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation). 44.Torque: 10 Nm x2 x6

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-136 303-01B-136 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 45.On both sides. E135112 46.Torque: 10 Nm x2 E134162 47.Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation). 48.Torque: 25 Nm x4 E131940 49. x7 E131904 50. x9 E131903 51. E129579

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-137 303-01B-137 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 52.Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 53.Torque: 30 Nm x4 E135111 54.Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures). 55.Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma (303-03 Engine Cooling - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures). 56.Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-138 303-01B-138 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION Engine Accessories(21 139 4) Installation Special Tool(s) / General Equipment 303-122 Lifting Bracket, Engine 21068A 303-1310 Holding Wrench, Crankshaft E87614 303-1317 Locking Tool, Fuel Injection Pump Sprocket E75376 303-249 Remover, Crankshaft Timing Pulley 21132 303-254 Locking Tool, Flywheel 21135 303-435 Mounting Stand 21187 Special Tool(s) / General Equipment 303-435-06 Mounting Bracket for 303-435 21031B 303-435-11B Mounting Plate for 303-435-06 E68386 303-679 Remover/Installer, Engine Front Cover Inspection Plate 303679 303-679A Remover/Installer, Engine Front Cover Inspection Plate E62024 308-204 Aligner, Clutch Disc 16067 1/2 Inch Square Drive Breaker Bar Dowel with a Diameter of 6 mm Materials Name Specification Silicone Sealant LB WSE-M4G323-A4 / 2U7J-M4G323-AA

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-139 303-01B-139 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 1. E131398 2. NOTE: Install the new crankshaft rear seal carrier within five minutes of applying the recommended sealant. Material: Silicone Sealant LB (WSE-M4G323-A4 / 2U7J-M4G323-AA) sealant 3mm E131393 3. CAUTION: 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. Initially hand tighten the fasteners. 2 4 6 7 3 1 8 5 E131394 4. NOTE: New crankshaft rear seal carriers are supplied with an alignment sleeve which must be removed after installation. Torque: 10 Nm 2 4 6 7 3 1 8 5 E131395 5. NOTE: Make sure that the flywheel is in full contact with the crankshaft flange before installing the flywheel bolts.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-140 303-01B-140 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION Initially hand tighten the fasteners. x8 E131396 6. Special Tool(s): 303-254 Torque: ‡ Stage 1: 15 Nm ‡ Stage 2: 30 Nm ‡ Stage 3: 75 Nm ‡ Stage 4: 45° 3 5 7 2 1 8 6 4 303-254 E131397 7. NOTE: The cone on the special tool must only be tightened finger tight to prevent damage to the clutch disc. Special Tool(s): 308-204 308-204 E129961 8. NOTE: Only tighten the bolt finger tight at this stage. Special Tool(s): 308-204 308-204 E129962

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-141 303-01B-141 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 9. CAUTION: Tighten the clutch pressure plate retaining bolts by two turns at a time in the sequence shown. Special Tool(s): 308-204 Torque: 45 Nm 1 6 4 308-204 3 2 5 E129963 10.Remove the Special Tool(s): 308-204 2 1 308-204 E129984 11. NOTE: Make sure that a new component is installed. Torque: 7 Nm E87416 12.Torque: 25 Nm E138700 13.Remove the Special Tool(s): 303-249 303-1317 303-249 E97222

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-142 303-01B-142 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 14.NOTE: Make sure that a new component is installed. Torque: 45 Nm E138701 15.Torque: 22 Nm E129689 16.Remove the Special Tool(s): 303-1317 303-1317 E97225 17.Remove the Special Tool(s): 303-679 303-679 E73839 18.Torque: 12 Nm x8 E138785 19.Torque: 23 Nm x6 E138791

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-143 303-01B-143 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 20.Torque: 23 Nm x2 E138793 21. 1. Torque: 48 Nm 2. Torque: 23 Nm 2 x2 1 22.Torque: 48 Nm x3 E134532 23.NOTE: Make sure that the mounting face is clean and lubricated. E131312 24. CAUTION: 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. Special Tool(s): 303-679A 303-679A E131365

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-144 303-01B-144 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 25.Remove the alignment sleeve after the seal is fully installed. E131367 2 x3 E131366 27.Torque: 9 Nm E138434 26. CAUTION: Crankshaft pulley retaining bolts must only be used three times. NOTE: Initially hand tighten the fasteners. Special Tool(s): 303-1310 Torque: ‡ Stage 1: 45 Nm ‡ Stage 2: 120° x3 1 303-1310 28. 1. Torque: 13 Nm 2. Torque: 3 Nm 1 x4 x4 2 E139598

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-145 303-01B-145 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 29.Torque: 10 Nm x9 E138427 30.Record the new fuel injector correction factor code. F100-0000 E129647 31.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. E129584 32. CAUTION: Make sure that new bolts are installed. Torque: ‡ Stage 1: 5 Nm ‡ Stage 2: 180° x2 E138483 33.Torque: ‡ Stage 1: 6 Nm ‡ Stage 2: 23 Nm x2 E129832 34.CAUTIONS: 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. Make sure that all openings are sealed. Use new blanking caps.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-146 303-01B-146 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION NOTE: Vacuum foreign material from the high-pressure fuel supply line, the fuel pump and the fuel rail. 1. Torque: ‡ Stage 1: 10 Nm ‡ Stage 2: 35 Nm 2. Refer to: Fuel Injection Component Cleaning (303-04 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: 12 Nm 2 2 1 1 E133928 35.Torque: ‡ Stage 1: 20 Nm ‡ Stage 2: 25 Nm x4 x4 E129581 36.Torque: 22 Nm x2 E138436 37.Torque: 12 Nm x2 E138425 38.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-147 303-01B-147 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION E138534 39.Torque: 25 Nm x3 E138424 40. CAUTION: Make sure that all openings are sealed. Use new blanking caps. E138426

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-148 303-01B-148 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 41.Torque: 25 Nm 1 x4 3 2 E130891 42. E135273 E138423 43. E135272 44.

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-149 303-01B-149 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 45. E138422 46.NOTE: The gasket is to be reused unless damaged. NOTE: The studs are to be reused unless damaged. x2 E138433 47. 1. Torque: 55 Nm 2. Torque: 40 Nm 3. Torque: 15 Nm 1 2 x6 x2 3 x3 E130782 48.Torque: 9 Nm x4 E138452 49.Torque: 25 Nm x2 E138430 50.Torque: 25 Nm E138429

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-150 303-01B-150 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 51.Torque: 25 Nm x4 E138459 52. CAUTION: Take extra care not to damage the wiring harnesses. 4. Torque: 15 Nm 5. Torque: 48 Nm 2 1 3 5 x3 4 E131417 53.General Equipment: 1/2 Inch Square Drive Breaker Bar General Equipment: Dowel with a Diameter of 6 mm

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-151 303-01B-151 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 1 E131377 54.Install the Special Tool(s): 303-122 303-122 E68699 2 55.Remove the Special Tool(s): 303-435-06, 303-435 303-435-06 303-435 E87394

Engine – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) 303-01B-152 303-01B-152 - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma INSTALLATION 56.Remove the Special Tool(s): 303-435-11B 303-435-11B E87393 57.Torque: 9 Nm 2 1 E139241 58.Torque: 23 Nm 1 x2 2 E134641 59. E138421 60.Torque: 10 Nm x2 E138420 61. 1. Torque: 35 Nm 2. Torque: 32 Nm 1 2 3 E138792