303-01C Motor 3.2 Duratorq

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-1 303-01C-1 . SECTION 303-01C Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma VEHICLE APPLICATION: 2011.50 Ranger CONTENTS SPECIFICATIONS Specifications...................................................................................................................... Engine Data.................................................................................................................... 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 View...................................................................................................................... Engine overview ............................................................................................................ Power and torque curves ............................................................................................... Engine type identification................................................................................................ Cylinder head.................................................................................................................. Electronic turbocharger guide vane adjustment............................................................. Oil level/temperature sensor........................................................................................... Service instruction.......................................................................................................... Engine (Component Location)............................................................................................ REMOVAL AND INSTALLATION Intake Manifold............................................................................................... Exhaust Manifold............................................................................................ Valve Cover.................................................................................................... Camshafts...................................................................................................... Valves................................................................................................................................. Valve Springs...................................................................................................................... Valve Stem Seals........................................................................................... Timing Cover.................................................................................................. Cylinder Head................................................................................................. Oil Pan............................................................................................................ Oil Pump......................................................................................................... Engine Front Seal............................................................................................................... Crankshaft Rear Seal..................................................................................... PAGE 303-01C-3 303-01C-3 303-01C-3 303-01C-3 303-01C-3 303-01C-4 303-01C-4 303-01C-4 303-01C-4 303-01C-4 303-01C-4 303-01C-5 303-01C-6 303-01C-6 303-01C-8 303-01C-8 303-01C-9 303-01C-9 303-01C-11 303-01C-11 303-01C-11 303-01C-12 (21 183 0) 303-01C-15 (21 187 0) 303-01C-18 (21 141 0) 303-01C-20 (21 284 0) 303-01C-22 303-01C-26 303-01C-28 (21 238 0) 303-01C-30 (21 146 0) 303-01C-31 (21 163 0) 303-01C-36 (21 154 0) 303-01C-39 (21 714 0) 303-01C-43 303-01C-45 (21 468 4) 303-01C-48

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-2 303-01C-2 . REMOVAL 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: 6-Speed Manual Transmission - MT82.................. Engine – Vehicles With: 6-Speed Automatic Transaxle - 6R80.................... Engine Accessories........................................................................................ (21 132 0; 21 132 6; 21 132 7) 303-01C-51 (21 132 0; 21 132 6; 21 132 7) 303-01C-60 (21 139 4) 303-01C-70 (21 134 8) 303-01C-83 (21 165 6) 303-01C-89 (21 134 8) 303-01C-90 (21 132 0; 21 132 6; 21 132 7) 303-01C-103 (21 132 0; 21 132 6; 21 132 7) 303-01C-112 (21 139 4) 303-01C-122

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-3 303-01C-3 SPECIFICATIONS Engine Data Description Code Firing order Bore diameter Stroke Displacement Compression ratio Power output at 3500 rpm Torque between 2000 to 2500 rpm Idle speed Maximum oil consumption Engine Oil Capacity Description Initial fill including oil filter Service fill including oil filter Service fill without oil filter Cylinder Block Dimensions Description Cylinder bore diameter – Class 1 Cylinder bore diameter – Class 2 Cylinder bore diameter – Class 3 Main bearing shells 1 to 5 inner diameter – bearings installed Main bearing shell 6 inner diameter – bearings installed Main bearings 1 to 5 radial clearance Main bearing 6 radial clearance Main bearings 1 to 5 parent bore diameter – vertical measurement Main bearing 6 parent bore diameter – vertical measurement Main bearings 1 to 5 parent bore diameter – horizontal measurement Main bearing 6 parent bore diameter – horizontal measurement Piston Dimensions Description Piston diameter – Class 1 Piston diameter – Class 2 Piston diameter – Class 3 Piston clearance in cylinder Piston ring end gaps 6$)$ 1-2-4-5-3 89.9 mm 100.76 mm 3198 cc 17.5:1 147 kW (200 PS) 470 Nm 800 +/- 50 rpm 0.1L / 1000 Km Liters 12,6 11,4 11,0 mm 89.900 - 89.910 89.910 - 89.920 89.920 - 89.930 64.994 - 65.022 69.994- 70.022 0.024 - 0.072 0.024 - 0.072 69.504 - 64.520 74.504 - 74.520 69.502 - 69.525 74.502 - 74.525 mm 89.84 - 89.85 89.85 - 89.86 89.86 - 89.87 0.05 - 0.07

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-4 303-01C-4 SPECIFICATIONS Description – upper compression ring – lower compression ring – oil control ring Piston ring gap position: The piston ring end gaps must be distributed evenly around the circumference of the piston. This also applies to the oil control ring elements. Align the piston ring end gaps at 120 degrees to each other. Crankshaft Dimensions Description Main bearing journal end float Main bearing journals 1 to 5 diameter Main bearing journal 6 diameter Connecting rod bearing journal diameter 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 mm 0.25 - 0.40 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 mm 55.996 - 56.016 32.010 - 32.018 53.016 - 53.046 0.026 - 0.084 0.100 - 0.320 mm 73.95 31.998 - 32.002 0.008 - 0.018 mm 0.014 - 0.200 26.440 - 26.465 0.04 - 0.09 mm 0.0625 - 0.0275 0.0725 - 0.0375 mm 0.10

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-5 303-01C-5 SPECIFICATIONS Description Peak to valley height of mating surface Cylinder head gasket thickness Piston protrusion of 0.310 - 0.400 mm Piston protrusion of 0.401 - 0.450 mm Piston protrusion of 0.451 - 0.500 mm Oil Pressure Specifications Description Minimum oil pressure at idle speed Minimum oil pressure at 2000 rpm Lubricants, Fluids, Sealers and Adhesives Item Ford Formula E SAE 5W-30 engine oil Sealer – oil pan, camshaft carrier and engine front cover mm 0.02 1.1 (one hole/tooth) 1.15 (two holes/teeth) 1.2 (three holes/teeth) bar 1.25 2.5 Specification WSS-M2C913-B WSE-M4G323-A4

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-6 303-01C-6 DESCRIPTION AND OPERATION Engine œ Overview General View ‡ The 3.2L Duratorq-TDCi (Puma) diesel engine is a five-cylinder inline engine which delivers a power of 147kW (200 PS). ‡ The engine is additionally equipped with an oil level/oil temperature sensor . ‡ The cylinder head consists of two parts and is made of aluminum. Both parts are bolted to each other. ‡ The lower part contains four valves for each combustion chamber and the two camshafts. ‡ The upper part houses the rocker arm frame with the roller rocker arms. The hydraulic valve clearance adjustment is integrated in the roller rocker arms. ‡ The camshafts and the fuel injection pump are driven by the crankshaft via the timing chain. ‡ The oil pump is located inside the oil pan and is driven by the crankshaft via a chain. NOTE: Cylinder 1 is located on the timing chain end.

303-01C-7 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-7 DESCRIPTION AND OPERATION E131231

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-8 303-01C-8 DESCRIPTION AND OPERATION Engine overview 6 5 4 3 2 1 E131900 1 $ E94909 Item Description 1 Oil pan 2 Oil pan extension 3 Cylinder block 4 Cylinder head lower part 5 Cylinder head upper part 6 Valve cover Power and torque curves 2 & %

303-01C- Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C- DESCRIPTION AND OPERATION Item Description $ Torque (Nm) % Engine speed (rpm) & Power (kW) Engine type identification X X X XXXXX X X XXXX E131233 Item Description 1 Engine code 2 Engine serial number On the 3.2L engine the engine code (4 digits) and the engine serial number (2 letters for the year and month and 5 figures for the serial number) are stamped in the cylinder block on the exhaust side (in line with cylinder no. 5). Item Description 1 Torque curve for the 147 kW engine (200 PS) 2 Power curve for the 147 kW engine (200 PS) If the engine or cylinder block is changed, the vehicle identification number must be stamped in the indicated location. Cylinder head

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-10 303-01C-10 DESCRIPTION AND OPERATION 5 4 E94935 Item Description 1 Cylinder head lower part 2 Cylinder head upper part 3 Rocker arm frame 3 2 1 Item Description 4 Camshafts 5 Roller rocker arms with hydraulic valve clearance adjustment

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-11 303-01C-11 DESCRIPTION AND OPERATION Electronic turbocharger guide vane adjustment E131898 Item Description 1 Electric actuator for turbocharger guide vane adjustment Oil level/temperature sensor E131899 An oil level/temperature sensor located on the front of the engine directly beside the engine oil dipstick is provided for the service interval indicator. A wire coil that is fitted inside the sensor and continuously supplied with current is used to measure the oil level. The resistance of the wire coil changes according to how deeply the sensor is immersed in the oil. The measurement values are registered by the Powertrain Control Module (PCM). The change in the voltage drop serves as an input variable for calculating the oil level. The oil temperature is sensed simultaneously via the integrated temperature sensor. The temperature is used as a corrective factor in the calculation. The PCM calculates the next oil change on the basis of an integrated strategy (which also takes into consideration the mileage and engine operating conditions) and displays it in the instrument panel. In addition, a separate indicator in conjunction with a corresponding message in the instrument cluster display warns the driver when the oil quantity falls below the minimum level. Service instruction The interval indicator must be reset after an oil change on all vehicles with a diesel engine. It must be ensured that the vehicle is standing on level ground.

303-01C-12 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-12 DESCRIPTION AND OPERATION Engine œ Component Location E131231

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-13 303-01C-13 DESCRIPTION AND OPERATION 7 6 8 5 1 2 3 4 E131232 Item Description 1 Turbocharger 2 Exhaust manifold 3 Oil pan 4 Flywheel 5 Vacuum pump 6 Fuel rail 10 11 12 13 Item Description 7 Valve cover 8 Thermostat Coolant pump 10 Fuel pump 11 Intake manifold 12 Oil cooler 13 EGR valve

303-01C-14 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-14 DESCRIPTION AND OPERATION X X X XXXXX X X XXXX E131233 Item Description 1 Engine code 2 Engine serial number

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-15 303-01C-15 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. 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. 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. E129579 4. E129866 5. E130889

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-16 303-01C-16 REMOVAL AND INSTALLATION 6. Torque: 11 Nm x2 E130890 7. Refer to: Exhaust Gas Recirculation (EGR) Valve - 3.2L Duratorq-TDCi (148kW/200PS) - 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). 8. 2. Torque: 10 Nm 3. Torque: 15 Nm 1 x4 3 2 E130891 9. E130892 10. E130893 11. E129686

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-17 303-01C-17 REMOVAL AND INSTALLATION 12.NOTE: Replace the o-ring, if necessary. NOTE: The gasket is to be reused unless damaged. Torque: 15 Nm x11 E130894 Installation 1. To install, reverse the removal procedure.

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-18 303-01C-18 REMOVAL AND INSTALLATION Exhaust Manifold(21 187 0) Removal NOTE: Removal steps in this procedure may contain installation details. 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. E131104 4. Refer to: Turbocharger - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, LHD 4WD/LHD RWD (303-04 Fuel Charging and Controls - Turbocharger, Removal and Installation). Refer to: Turbocharger - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, RHD 4WD/RHD 5:' (303-04 Fuel Charging and Controls - Turbocharger, Removal and Installation). Refer to: Generator - 3.2L Duratorq-TDCi (148kW/200PS) - Puma (414-02 Generator and Regulator, Removal and Installation). 5. E132022 6. 1. Torque: 9 Nm 2. Torque: 22 Nm 3. Torque: 25 Nm 2 1 x5 x2 x2 3 E131140

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-19 303-01C-19 REMOVAL AND INSTALLATION 7. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 8. Remove front RH side wheel only. Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation). 9. Torque: 10 Nm E132699 10.CAUTIONS: Make sure that new nuts are installed. Make sure that new bolts are installed. 1. Torque: 40 Nm 2. Torque: 23 Nm 1 x10 2 x3 E131141 11. CAUTION: Make sure that new studs are installed. NOTE: The gasket is to be reused unless damaged. E131142 Installation 1. To install, reverse the removal procedure.

303-01C-20 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-20 REMOVAL AND INSTALLATION Valve Cover(21 141 0) Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation). Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 2. E131104 3. Refer to: Fuel Injectors (303-04 Fuel Charging and Controls - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 4. 1. Torque: ‡ Stage 1: 5 Nm ‡ Stage 2: 35 Nm 2. Torque: 10 Nm x3 2 1 1 E133633 5. Torque: 10 Nm x9 x3 E131105

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-21 303-01C-21 REMOVAL AND INSTALLATION 6. NOTE: The gasket is to be reused unless damaged. E134582 Installation 1. To install, reverse the removal procedure.

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-22 303-01C-22 REMOVAL AND INSTALLATION Camshafts(21 284 0) Special Tool(s) / General Equipment 100-010 Remover, O-Ring Seal 17063 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 - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). Refer to: Valve Cover (303-01 Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). Refer to: Timing Cover (303-01 Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). Refer to: Brake Vacuum Pump - 3.2L Duratorq-TDCi (148kW/200PS) - Puma (206-07 Power Brake Actuation, Removal and Installation). 2. Special Tool(s): 100-010 General Equipment: 2 mm Punch 100-010 100-010 2 2 1 1 3 3 E87423 3. General Equipment: 2 mm Punch E87424

303-01C-23 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-23 REMOVAL AND INSTALLATION 4. x2 x3 x3 x2 x2 E95464 5. 11 7 3 1 5 2 6 10 12 8 4 E94096 6. x2 E94111 Installation 1. NOTE: Clean the mating faces of the camshaft carrier and the cylinder head. Torque: ‡ Bolts 1 to 26 ‡ Stage 1: 3,5 Nm ‡ Stage 2: 15 Nm ‡ Stage 3: 23 Nm ‡ Bolts 27 and 28 ‡ Stage 1: 3,5 Nm ‡ Stage 2: 7,5 Nm ‡ Stage 3: 10 Nm 26 22 14 8 6 16 24 18 10 4 2 12 20 17 3 1 11 19 25 21 13 7 15 23 5 27 28 E94486 2. NOTE: Make sure that the rocker arms do not separate. Torque: ‡ Stage 1: 10 Nm ‡ Stage 2: 30° 11 7 3 1 5 4 2 6 10 12 8 E94096

303-01C-24 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-24 REMOVAL AND INSTALLATION 3. Special Tool(s): 303-1562 303-1562 E138698 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 bit. 6. Torque: ‡ 1 15 Nm ‡ 2 40 Nm ‡ 3 40 Nm x2 1 x2 1 2 x2 3 E95442 7. NOTE: Make sure that a new component is installed. Torque: 15 Nm x2 E75760 8. Remove the Special Tool(s): 303-1562 303-1562 E138698 9. Rotate the engine two revolutions.

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-25 303-01C-25 REMOVAL AND INSTALLATION 10.Special Tool(s): 303-1562 303-1562 E138698 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 - 3.2L Duratorq-TDCi (148kW/200PS) - Puma (206-07 Power Brake Actuation, Removal and Installation). Refer to: Timing Cover (303-01 Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). Refer to: Valve Cover (303-01 Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). Refer to: Fuel Rail (303-04 Fuel Charging and Controls - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation).

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-26 303-01C-26 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 - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 2. NOTE: Position a socket on the valve spring seat and gently strike it with a hammer. ELE0015706 Special Tool(s) 303-060-07 Adapter for 303-060 2102407 303-362 Installer, Valve Stem Collets 21156 3. Special Tool(s): 303-060, 303-060-05, 303-060-07, 303-362 303-060 303-060 303-362 303-060-05 303-060-05 303-060-07 303-060-07 E95039

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-27 303-01C-27 REMOVAL AND INSTALLATION 4. E139000 Installation 1. To install, reverse the removal procedure.

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-28 303-01C-28 REMOVAL AND INSTALLATION Valve Springs Special Tool(s) 303-060 Compressor, Valve Spring 21024 303-060-05 Adapter for 303-060 2102405 Removal 1. Refer to: Valve Cover (303-01 Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 2. x12 11 7 3 1 5 12 8 4 2 6 10 E94096 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. Special Tool(s): 303-060, 303-060-05, 303-060-07, 303-362 303-060 303-362 303-060-05 303-060-07 303-060-07 E95544

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-29 303-01C-29 REMOVAL AND INSTALLATION Installation 1. Special Tool(s): 303-060, 303-060-05, 303-060-07, 303-362 303-060 303-362 303-060-05 303-060-07 303-060-07 E95544 2. Torque: ‡ Stage 1: 10 Nm ‡ Stage 2: 30° x12 11 7 3 1 5 12 8 4 2 6 10 E94096 3. Refer to: Valve Cover (303-01 Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation).

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-30 303-01C-30 REMOVAL AND INSTALLATION Valve Stem Seals(21 238 0) Special Tool(s) 303-508 Pliers, Valve Stem Seal 21211 Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Valve Springs (303-01 Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 2. Special Tool(s): 303-508 303-508 E95598 Installation 1. To install, reverse the removal procedure.

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-31 303-01C-31 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 - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 3. Refer to: Generator - 3.2L Duratorq-TDCi (148kW/200PS) - Puma (414-02 Generator and Regulator, Removal and Installation). 4. 1. Torque: 35 Nm 2. Torque: 35 Nm x2 2 x2 1 E134536 5. 1. Torque: 48 Nm 2. Torque: 23 Nm 2 x2 1 E131304

303-01C-32 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-32 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 side 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

303-01C-33 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-33 REMOVAL AND INSTALLATION 13. 1. Torque: 20 Nm 2. Torque: 20 Nm 3. Torque: 18 Nm 1 2 3 E134533 14.Torque: 10 Nm E129991 15. E129992 16. 3. Torque: 23 Nm 3 x3 2 1 E134534 17.Torque: 23 Nm 1 2 E134535

303-01C-34 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-34 REMOVAL AND INSTALLATION 18.Refer to: Engine Front Seal (303-01 Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 19.Special Tool(s): 303-428 2 x20 303-428 1 x2 E131307 Installation 1. CAUTION: Install the timing cover 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 E131310

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-35 303-01C-35 REMOVAL AND INSTALLATION 2. 1. Special Tool(s): 303-682 Torque: 10 Nm 2. Torque: 14 Nm 1 x20 303-682 2 x2 E131309 3. To install, reverse the removal procedure.

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-36 303-01C-36 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) 21183 Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Intake Manifold (303-01 Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). Refer to: Brake Vacuum Pump - 3.2L Duratorq-TDCi (148kW/200PS) - Puma (206-07 Power Brake Actuation, Removal and Installation). Refer to: Exhaust Gas Recirculation (EGR) Cooler - 3.2L Duratorq-TDCi (148kW/200PS) - 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). Refer to: Exhaust Manifold (303-01 Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). Refer to: Camshafts (303-01 Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 2. 2 3 x12 x10 1 E131631 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

303-01C-37 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-37 REMOVAL AND INSTALLATION paths. Use a plastic scraping tool to remove all traces of the head gasket. E131632 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): 205-069, 205-070, 303-432 205-070 303-432 205-069 E131634 4. NOTE: Note the thickness of the gasket. NOTE: Make sure that a new component is installed. E131635 5. E131636 6. CAUTION: Make sure that new cylinder head bolts are installed. Torque: ‡ Bolts 1 to 12: 10 Nm ‡ Bolts 13 to 22: 5 Nm ‡ Bolts 1 to 12: 20 Nm ‡ Bolts 13 to 22: 10 Nm ‡ Bolts 1 to 12: 50 Nm ‡ Bolts 1 to 12: 180° ‡ Bolts 13 to 22: 25 Nm ‡ Bolts 13 to 22: 180° 21 6 18 2 14 4 10 16 7 20 11 22 12 5 17 1 13 3 15 8 19 E131637

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-38 303-01C-38 REMOVAL AND INSTALLATION 7. Refer to: Camshafts (303-01 Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). Refer to: Exhaust Manifold (303-01 Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). Refer to: Exhaust Gas Recirculation (EGR) Cooler - 3.2L Duratorq-TDCi (148kW/200PS) - 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). Refer to: Brake Vacuum Pump - 3.2L Duratorq-TDCi (148kW/200PS) - Puma (206-07 Power Brake Actuation, Removal and Installation). Refer to: Intake Manifold (303-01 Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation).

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-39 303-01C-39 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. x4 1 E133766 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 5. Torque: 30 Nm 2

303-01C-40 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-40 REMOVAL AND INSTALLATION All vehicles 6. Torque: 30 Nm 1 x4 2 E128859 3 x2 x2 2 E133875 9. WARNING: Be prepared to collect escaping fluids. 7. Torque: 35 Nm x4 x4 x3 E130951 8. CAUTION: Take extra care when handling steering gear rack. 1. Torque: 23 Nm 2. Torque: 150 Nm 1

303-01C-41 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-41 REMOVAL AND INSTALLATION Drain the oil pan into a suitable container. Torque: 39 Nm 2 1 E130800 10.Special Tool(s): 303-428 x18 303-428 E130952 11. Torque: 10 Nm E130953 12.Torque: 10 Nm E130954 4x4 13. E130955

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-42 303-01C-42 REMOVAL AND INSTALLATION 4x2 14. E133876 Installation 1. NOTE: Do not damage the mating faces. Special Tool(s): 303-428 303-428 E133924 2. 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 3. Torque: ‡ Stage 1: 7 Nm ‡ Stage 2: 14 Nm 11 4 12 1 13 5 7 10 14 3 2 16 6 18 8 17 15 E130957 4. To install, reverse the removal procedure. 5. Fill the oil pan with clean engine oil. Refer to: Specifications (303-01 Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Specifications).

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-43 303-01C-43 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. 1. Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation). Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 2. Refer to: Oil Pan (303-01 Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 3. Hand tighten the bolts at this stage. Special Tool(s): 303-705 Torque: 15 Nm 2 x2 1 303-705 E131539 4. WARNING: Be prepared to collect escaping fluids. Torque: 13 Nm 2 1 E131540 5. NOTE: Do not completely loosen the bolts at this stage. Special Tool(s): 303-705 303-705 x4 E131541

303-01C-44 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-44 REMOVAL AND INSTALLATION 6. Special Tool(s): 303-705 303-705 2 3 x4 1 E131542 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 2 1 E131543 2. NOTE: Hand tighten the bolts at this stage. Special Tool(s): 303-705 303-705 x4 E131541 3. Torque: 10 Nm 3 2 x2 x4 1 E131544 4. Refer to: Oil Pan (303-01 Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation).

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-45 303-01C-45 REMOVAL AND INSTALLATION Engine Front Seal Special Tool(s) 303-1310 Holding Wrench, Crankshaft E87614 Removal NOTE: Removal steps in this procedure may contain installation details. 1 x3 E131305 3. CAUTION: Rotate the seal assembly until it releases. Failure to follow this Special Tool(s) 303-679A Remover/Installer, Engine Front Cover Inspection Plate E62024 1. Refer to: Cooling Fan Motor and Shroud (303-03 Engine Cooling - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 2. 1.Do not completely loosen the crankshaft pulley bolts. Special Tool(s): 303-1310 X2 x3 2 303-1310

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-46 303-01C-46 REMOVAL AND INSTALLATION instruction may result in damage to the seal assembly. Special Tool(s): 303-679A 303-679A E131306 Installation 1. NOTE: Make sure that the mounting face is clean and lubricated. E131312 2. 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 3. Remove the alignment sleeve after the seal is fully installed. E131367 4. CAUTION: The crankshaft pulley bolts must not be used more than 3 times. Special Tool(s): 303-1310 Torque: ‡ Stage 1: 45 Nm ‡ Stage 2: 120°

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-47 303-01C-47 REMOVAL AND INSTALLATION 2 x3 E131366 5. Refer to: Cooling Fan Motor and Shroud (303-03 Engine Cooling - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). x3 1 303-1310

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-48 303-01C-48 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: 6-Speed Manual Transmission - MT82, Removal and Installation). All vehicles 3. Special Tool(s): 303-254 x8 303-254 E131391

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-49 303-01C-49 REMOVAL AND INSTALLATION 4. x8 E131392 Installation All vehicles 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. Hand tighten the bolts at this stage. 2 4 6 7 3 1 8 5 E131394

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-50 303-01C-50 REMOVAL AND INSTALLATION 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. Hand tighten the bolts at this stage. 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 Vehicles with manual transmission 7. 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).

303-01C-51 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-51 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. x4 E130132 7. 1 x4 2 E128859 8. E129579 9. x9 E131903

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-52 303-01C-52 REMOVAL 10. x7 E131904 11. x4 E131940 12.Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation). 13. x2 E134162 14.On both sides. E128788 15.

303-01C-53 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-53 REMOVAL x7 E133552 16. E135105 x2 x6 17. E135104

303-01C-54 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-54 REMOVAL 18.Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation). 19.Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation). 20.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). 21. x4 E139349 22. x2 E139350 23. x2 E130890 24. 2 1 E134703

303-01C-55 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-55 REMOVAL 25. E132020 26.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). 27.Refer to: Radiator (303-03 Engine Cooling - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 28.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). 29. E135125 30.Refer to: Starter Motor - 3.2L Duratorq-TDCi (148kW/200PS) - 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). 31. E131212 32. E129816

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-56 303-01C-56 REMOVAL 33.Refer to: Air Cleaner - 3.2L Duratorq-TDCi (148kW/200PS) - 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. E132021 35. CAUTION: Cap the power steering line to prevent fluid loss or dirt ingress. 2 1 x2 3 E133693 36. E134704 37. E132022 38. x2 E130529

303-01C-57 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-57 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 E134706 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.

303-01C-58 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-58 REMOVAL Tie and support the transmission to the chassis with a suitable strap. General Equipment: Transmission Jack E128845 46. x3 E132702 47. x2 x4 E132701 48.On both sides. E132028 49.Special Tool(s): 303-122 303-122 E68699

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-59 303-01C-59 REMOVAL 50. E132036 51. x3 2 1 E132029

303-01C-60 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-60 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. x4 E130132 7. 1 x4 2 E128859 8. E129579 9. x9 E131903

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-61 303-01C-61 REMOVAL 10. x7 E131904 11. x4 E131940 12.Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation). 13. x2 E134162 14.On both sides. E128788 15.

303-01C-62 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-62 REMOVAL x7 E133552 16. E135105 x2 x6 17. E135104

303-01C-63 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-63 REMOVAL 18.Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation). 19.Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation). 20.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). 21. x4 E139349 22. x2 E139350 23. x2 E130890 24. 2 1 E134703

303-01C-64 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-64 REMOVAL 25. E132020 26.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). 27.Refer to: Radiator (303-03 Engine Cooling - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 28.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). 29. E135125 30.Refer to: Starter Motor - 3.2L Duratorq-TDCi (148kW/200PS) - 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). 31. E131212 32.Refer to: Transmission Fluid Cooler (307-02 Transmission/Transaxle Cooling, Removal and Installation). 33. E129816

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-65 303-01C-65 REMOVAL 34.Refer to: Air Cleaner - 3.2L Duratorq-TDCi (148kW/200PS) - 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). 35.NOTE: Make sure that all openings are sealed. E132021 36. CAUTION: Cap the power steering line to prevent fluid loss or dirt ingress. 2 1 3 E133693 37. E134704 38. E132022 39. x2 E130529

303-01C-66 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-66 REMOVAL 40.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). 41. E134705 42. 1 2 E134706 43. E132699 44. E134708 45. E134707 46. 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 – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-67 303-01C-67 REMOVAL Tie and support the transmission to the chassis with a suitable strap. General Equipment: Transmission Jack E128845 47. x2 x3 E135451 48. x2 E135453 49.

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-68 303-01C-68 REMOVAL 2 E135454 50. x2 E135452 303-1310 1 x6 2 51.On both sides. E132028 52.Special Tool(s): 303-122 303-122 E68699

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-69 303-01C-69 REMOVAL 53. E132036 54. x3 2 1 E132029

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-70 303-01C-70 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 E62024 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

303-01C-71 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-71 REMOVAL 2. 1 2 3 E138792 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

303-01C-72 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-72 REMOVAL 8. Install the Special Tool(s): 303-435-06, 303-435 303-435-06 303-435 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 – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-73 303-01C-73 REMOVAL 11. CAUTION: Take extra care not to damage the wiring harnesses. 2 1 3 5 x3 4 E131417 12. x4 E138459 13. E138429 14. x2 E138430 15. x5 E138787

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-74 303-01C-74 REMOVAL 16. 1 x10 2 x3 E131141 17.NOTE: The gasket is to be reused unless damaged. NOTE: The studs are to be reused unless damaged. E131142 18. E138422 19. E135272 20. E135273 21.

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-75 303-01C-75 REMOVAL E138790

303-01C-76 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-76 REMOVAL 22. E135428 23. 1 x4 3 2 E130891 24. E130893 25. CAUTION: Make sure that all openings are sealed. Use new blanking caps. E138788 26. x3 E138424 27. E138786

303-01C-77 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-77 REMOVAL 28. x2 E138425 29. x2 E138436 30. x3 E87416 31.Special Tool(s): 303-254 303-254 E133584 32.NOTE: Do not loosen the bolts more than 2 turns. 6 1 4 X2 3 2 5 E129960

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-78 303-01C-78 REMOVAL 33.Special Tool(s): 303-254 x8 303-254 E131391 34. x8 E131392 35. x11 E130894 36. x5 x5 E129826 37.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. x3 2 1 1 E133633

303-01C-79 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-79 REMOVAL 38. x2 E129832 39. x4 E129828 40. E129584 41. 2 x5 x5 1 E138789 42. E135430 43. E138434

303-01C-80 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-80 REMOVAL 44.Special Tool(s): 303-679 303-679 E129923 45. E97216 46.Special Tool(s): 303-1317 303-1317 E97221 47. E129689 48.Special Tool(s): 303-1317, 303-249 303-1317 303-249 E97222 49. x3 E129690

303-01C-81 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-81 REMOVAL 50. 2 x2 1 E131304 51. x2 E138793 52. x6 E138791 53. x8 E138785 54. x3 E134532 55.Special Tool(s): 303-1310

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-82 303-01C-82 REMOVAL 1 x3 E131305 56.Special Tool(s): 303-679A 303-679A E131306 X2 x3 2 303-1310

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-83 303-01C-83 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: 23 Nm x3 E129690 2. NOTE: Make sure that a new component is installed. Torque: 45 Nm E138701

303-01C-84 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-84 DISASSEMBLY 3. Torque: 22 Nm E129689 4. Remove the Special Tool(s): 303-1317, 303-249 303-1317 303-249 E97222 5. Remove the Special Tool(s): 303-1317 303-1317 E97221 6. Remove the Special Tool(s): 303-679 303-679 E129923 7. x20 x2 E75620 8. Special Tool(s): 303-428 303-428 E87411

303-01C-85 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-85 DISASSEMBLY 9. E94201 10.Special Tool(s): 100-010 General Equipment: 2 mm Punch 100-010 2 1 3 E87423 11. Remove and discard the timing chain tensioner. General Equipment: 2 mm Punch E87424 12. x8 x4 E138963 13.NOTE: The gasket is to be reused unless damaged. E131106 14. x2 x3 x3 x2 x2 E95464

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-86 303-01C-86 DISASSEMBLY 15. 11 7 3 1 12 8 4 2 6 10 E94096 16. x2 E94111 17. 22 6 18 2 14 4 16 8 20 11 10 12 21 17 1 13 3 15 7 19 E94113 18. WARNING: Be prepared to collect escaping fluid. 2 1 E130800 19.Special Tool(s): 303-428 303-428 x18 E138964 20. E76144

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-87 303-01C-87 DISASSEMBLY 21. x6 E138437 22. E94117 23. E95356 24.NOTE: Note the position of each component before removal. x10 E94118 25.NOTE: Note the position of each component before removal. E94157 26.NOTE: Note the position of each component before removal. E94158

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-88 303-01C-88 DISASSEMBLY 27.NOTE: Note the position of each component before removal. x12 E94161 28.NOTE: Note the position of each component before removal. E94173 29.NOTE: Note the position of each component before removal. 3 1 x5 x5 2 E138965

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-89 303-01C-89 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Cylinder Head(21 165 6) Disassembly 1. For additional information, refer to: Valves (303-01 Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 2. Torque : 13Nm x5 E138395 3. Torque : 23Nm x2 E138008 Assembly 1. To assemble, reverse the disassembly procedure.

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-90 303-01C-90 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

303-01C-91 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-91 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 x5 x5 2 E138965 2. NOTE: Make sure that these components are installed to the noted removal position. Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil E94362 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° x12 E94161 4. NOTE: Make sure that these components are installed to the noted removal position. General Equipment: Piston Ring Compressor Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil XXXX X5X5XXX x5 E94363

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-92 303-01C-92 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 E94387 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° x10 E94118 7. E95356 8. NOTE: Only tighten the bolts finger tight at this stage. E94117 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 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

303-01C-93 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-93 ASSEMBLY 11. Torque: 23 Nm 12 19 24 8 11 22 14 15 7 3 2 6 18 17 16 20 4 1 5 10 13 25 21 23 E94393 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 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

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-94 303-01C-94 ASSEMBLY 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.Material: Engine Oil - 5W-30 (WSS-M2C913-C) engine oil E131398 19.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 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. Initially hand tighten the fasteners. 2 4 6 7 3 1 8 5 E131394

303-01C-95 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-95 ASSEMBLY 21.NOTE: New crankshaft rear 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 the flywheel is in full contact with the crankshaft flange before installing the flywheel bolts. Initially hand tighten the fasteners. x8 E131396 23.Special Tool(s): 303-254 Torque: ‡ Stage 1: 15 Nm ‡ Stage 2: 30 Nm ‡ Stage 3: 75 Nm 3 5 7 2 1 8 4 6 303-254 E131397 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 E87418

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-96 303-01C-96 ASSEMBLY 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, 205-070 205-070 205-069 TIE0034799 28.Zero the dial indicator gauge. 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): 303-391 303-391 TIE0034803 31.Repeat the previous steps to make sure that the marking is correct. 32.NOTE: The middle of the markings is TDC. Measure the distance between the two marks. TIE0034804 33.Divide the amount by two and mark the position TDC on the flywheel primary mass.

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-97 303-01C-97 ASSEMBLY 34.Measure the circumference of the flywheel primary mass. TIE0034809 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 paths. Use a plastic scraping tool to remove all traces of the head gasket. E131632

303-01C-98 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-98 ASSEMBLY 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 - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Specifications). 43.NOTE: Make sure that a new component is installed. E94452 44. E131636 45. CAUTION: Make sure that new cylinder head bolts are installed. Torque: ‡ Bolts 1 to 12: 10 Nm ‡ Bolts 13 to 22: 5 Nm ‡ Bolts 1 to 12: 20 Nm ‡ Bolts 13 to 22: 10 Nm ‡ Bolts 1 to 12: 180° ‡ Bolts 1 to 12: 50 Nm ‡ Bolts 13 to 22: 180° ‡ Bolts 13 to 22: 25 Nm 21 6 18 2 14 4 10 16 7 20 11 22 12 5 17 1 13 3 15 8 19 E131637

303-01C- Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C- ASSEMBLY 46.Material: Silicone Sealant LB (WSE-M4G323-A4 / 2U7J-M4G323-AA) sealant m 2 2,5mm E95380 47.Torque: ‡ Bolts 1 to 26 23 Nm ‡ Bolts 27, 28 10 Nm 26 22 14 8 6 16 24 18 10 4 2 12 20 19 17 3 1 11 25 21 13 7 5 15 23 27 28 E94486 48.Torque: ‡ Stage 1: 10 Nm ‡ Stage 2: 30° 11 7 3 1 5 12 8 4 2 6 10 E94096 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.

303-01C-100 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-100 ASSEMBLY 52. 1. Torque: 15 Nm 2. Torque: 40 Nm 3. CAUTION: Make sure that new bolts are installed. 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 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. General Equipment: 6 mm Drill Bit E95424 58.Remove the 6 mm drill bits. 59.Remove the Special Tool(s): 303-1562 303-1562 E138698

303-01C-101 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-101 ASSEMBLY 60. E131106 61.Torque: 10 Nm x8 x4 E138963 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. 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 14 Nm 303-682 1 2 x2 x20 E87427

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-102 303-01C-102 ASSEMBLY 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 67.Torque: ‡ Stage 1: 12 Nm ‡ Stage 2: 15 Nm 11 4 12 1 13 5 7 10 14 3 2 16 6 18 8 17 15 E130957 68.NOTE: The seal is to be reused unless damaged. Torque: 35 Nm 2 1 E130800

303-01C-103 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-103 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. E135148 4. NOTE: Hand tighten the nut at this stage. E132028 5. NOTE: Hand tighten the nuts at this stage. x3 2 1 E132029 6. NOTE: Hand tighten the nut at this stage. E135094

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-104 303-01C-104 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: 25 Nm x3 2 1 E132029 11. Torque: 80 Nm E135094 12. 1. Remove the Special Tool(s): 303-122 303-122 E68699

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-105 303-01C-105 INSTALLATION 13.Torque: 13 Nm E134707 14. E134708 15.Torque: 12 Nm E132699 16. E134705 17.Torque: 10 Nm 1 2 E134706

303-01C-106 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-106 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.Torque: 22 Nm x2 E130529 20. E132022 21. E134704 22.Torque: 35 Nm 2 1 x2 3 E133693 23. E132021

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-107 303-01C-107 INSTALLATION 24.Torque: 22 Nm E135146 25.Refer to: Starter Motor - 3.2L Duratorq-TDCi (148kW/200PS) - 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 - 3.2L Duratorq-TDCi (148kW/200PS) - 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 - 3.2L Duratorq-TDCi (148kW/200PS) - 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. E129816

303-01C-108 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-108 INSTALLATION 32. E135147 33.Torque: 10 Nm x2 E130890 34.Torque: 18 Nm x2 E139350 35.Torque: 5 Nm E135105 36. E135104

303-01C-109 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-109 INSTALLATION 37. x4 E139349 x7 E133552 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 x2 x6

303-01C-110 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-110 INSTALLATION 42.On both sides. E128788 43.Torque: 10 Nm x2 E134162 44.Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation). 45.Torque: 25 Nm x4 E131940 46. x7 E135145 47. x9 E131903 48.Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 49.Torque: 30 Nm x4 E135111

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-111 303-01C-111 INSTALLATION 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).

303-01C-112 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-112 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. E135148 4. NOTE: Hand tighten the nut at this stage. E132028 5. NOTE: Hand tighten the nuts at this stage. x3 2 1 E132029 6. NOTE: Hand tighten the nut at this stage. E135094

303-01C-113 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-113 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 x3 2 1 E132029 11. Torque: 80 Nm E132028 12. 1. Remove the Special Tool(s): 303-122 303-122 E68699

303-01C-114 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-114 INSTALLATION 13.Torque: 13 Nm E134707 2 E135454 14.Torque: 40 Nm 303-1310 60 1 x6 2

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-115 303-01C-115 INSTALLATION 15.Torque: 22 Nm x2 E135453 16. E134708 17.Torque: 12 Nm E132699 18. E134705 19.Torque: 10 Nm 1 2 E134706

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-116 303-01C-116 INSTALLATION 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.Torque: 22 Nm x2 E130529 22. E132022 23. E134704 24.Torque: 35 Nm 2 1 x2 3 E133693 25. E132021

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-117 303-01C-117 INSTALLATION 26.Torque: 22 Nm E135146 27.Refer to: Starter Motor - 3.2L Duratorq-TDCi (148kW/200PS) - 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 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 - 3.2L Duratorq-TDCi (148kW/200PS) - 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 - 3.2L Duratorq-TDCi (148kW/200PS) - 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. E129816

303-01C-118 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-118 INSTALLATION 35. E135147 36.Torque: 10 Nm x2 E130890 37.Torque: 18 Nm x2 E139350 38.Torque: 5 Nm E135105 39. E135104

303-01C-119 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-119 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

303-01C-120 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-120 INSTALLATION 45.On both sides. E128788 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 E135145 50. x9 E131903 51.Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 52.Torque: 30 Nm x4 E135111

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-121 303-01C-121 INSTALLATION 53.Torque: 20 Nm x4 E130132 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 – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-122 303-01C-122 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 – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-123 303-01C-123 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: 20 Nm 2 4 6 7 3 1 8 5 E131395

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-124 303-01C-124 INSTALLATION 5. Special Tool(s): 303-254 303-254 E133584 6. NOTE: Make sure that the flywheel is in full contact with the crankshaft flange before installing the flywheel bolts. Initially hand tighten the fasteners. x8 E131396 7. Special Tool(s): 303-254 Torque: ‡ Stage 1: 15 Nm ‡ Stage 2: 30 Nm ‡ Stage 3: 75 Nm 3 5 7 2 1 8 4 6 303-254 E131397 8. 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

303-01C-125 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-125 INSTALLATION 9. NOTE: Only tighten the bolt finger tight at this stage. Special Tool(s): 308-204 308-204 E129962 10. 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 6 1 4 308-204 3 2 5 E129963 11. Remove the Special Tool(s): 308-204 2 1 308-204 E129984 12.NOTE: Make sure that a new component is installed. Torque: 7 Nm x3 E87416

303-01C-126 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-126 INSTALLATION 13.Torque: 23 Nm x3 E129690 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, 303-249 303-1317 303-249 17.Remove the Special Tool(s): 303-1317 303-1317 E97221

303-01C-127 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-127 INSTALLATION 18.Remove the Special Tool(s): 303-679 303-679 E129923 19.Torque: 12 Nm x8 E138785 20.Torque: 23 Nm x6 E138791 21.Torque: 23 Nm x2 E138793 22. Torque: 48Nm 1. 2. Torque: 23 Nm 2 x2 1 E131304 23.Torque: 48 Nm x3 E134532

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-128 303-01C-128 INSTALLATION 24.NOTE: Make sure that the mounting face is clean and lubricated. E131312 25. 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 26.Remove the alignment sleeve after the seal is fully installed. E131367 27. 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°

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-129 303-01C-129 INSTALLATION 2 x3 E131366 28.Torque: 9 Nm E138434 29. 2 x5 x5 1 E138789 x3 1 303-1310 30.Torque: 15 Nm x11 E130894 31.Record the new fuel injector correction factor code. F100-0000 E129647 32.NOTE: Using a socket (or similar), press the new fuel injector copper seals onto the fuel

303-01C-130 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-130 INSTALLATION injectors making sure that the copper seals are pushed fully home to prevent uneven clamping. E129584 33. CAUTION: Make sure that new bolts are installed. Torque: ‡ Stage 1: 5 Nm ‡ Stage 2: 180° x4 E129828 34.Torque: ‡ Stage 1: 7 Nm ‡ Stage 2: 20 Nm x2 E129832 35.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. 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 x3 2 1 1 E133633 36.Torque: ‡ Stage 1: 20 Nm ‡ Stage 2: 25 Nm x5 x5 E129826

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-131 303-01C-131 INSTALLATION 37.Torque: 22 Nm x2 E138436 38.Torque: 12 Nm x2 E138425 39. E138786 40.Torque: 25 Nm x3 E138424 41. CAUTION: Make sure that all openings are sealed. Use new blanking caps. E138788 42. E130893

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-132 303-01C-132 INSTALLATION 43. 3. Torque: 25 Nm 1 x4 3 2 E130891 44. E135273 45. E135272 46.

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-133 303-01C-133 INSTALLATION E138790

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-134 303-01C-134 INSTALLATION 47. E138422 48.NOTE: The gasket is to be reused unless damaged. NOTE: The studs are to be reused unless damaged. E131142 49. 1. Torque: 40 Nm 2. Torque: 23 Nm 1 x10 2 x3 E131141 50.Torque: 9 Nm x5 E138787 51.Torque: 20 Nm x2 E138430 52.Torque: 25 Nm E138429

Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-135 303-01C-135 INSTALLATION 53.Torque: 25 Nm x4 E138459 54. 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 55.General Equipment: 1/2 Inch Square Drive Breaker Bar General Equipment: Dowel with a Diameter of 6 mm

303-01C-136 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-136 INSTALLATION 1 E131377 56.Install the Special Tool(s): 303-122 303-122 E68699 2 57.Remove the Special Tool(s): 303-435-06, 303-435 303-435-06 303-435 E87394

303-01C-137 Engine – 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-137 INSTALLATION 58.Remove the Special Tool(s): 303-435-11B 303-435-11B E87393 59.Torque: 9 Nm 1 2 E138440 60.Torque: 23 Nm 1 x2 2 E134641 61. E138421 62.Torque: 10 Nm x2 E138420 63. 1. Torque: 35 Nm 2. Torque: 32 Nm 1 2 3 E138792