303-03A Arrefecimento do motor 2.2

Engine Cooling – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-1 303-03A-1 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma . SECTION 303-03A Engine Cooling – 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...................................................................................................................... DESCRIPTION AND OPERATION Engine Cooling................................................................................................................... Vehicles with 2.2L Duratorq-TDCi (Puma) diesel engine................................................... GENERAL PROCEDURES 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.......................................................................................................... Draining.............................................................................................................................. Filling.................................................................................................................................. Bleeding.............................................................................................................................. REMOVAL AND INSTALLATION Thermostat..................................................................................................... Thermostat Housing....................................................................................... Coolant Pump................................................................................................. Radiator.......................................................................................................... Cooling Fan Motor and Shroud...................................................................... Coolant Outlet Connector................................................................................................... PAGE 303-03A-2 303-03A-3 303-03A-3 (24 122 0) 303-03A-5 303-03A-5 303-03A-5 303-03A-5 (24 454 0) 303-03A-7 (24 001 0) 303-03A-8 (24 404 0) 303-03A-9 (24 254 0) 303-03A-11 (24 222 0) 303-03A-13 303-03A-15

Engine Cooling – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-2 303-03A-2 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma SPECIFICATIONS Antifreeze Specifications Description Motorcraft Super Plus 2000 Specific gravity (providing no other additive is in the coolant) Approximate percentage of antifreeze (by volume) Coolant remains fluid to Coolant solidifies at Cooling System Capacities – Vehicles with 2.2L Diesel Engine Description Vehicles with front heater only Cooling System Pressure Specification Description Radiator pressure test Coolant expansion tank cap release pressure Specification WSS-M97B44-D 1.068 at +15°C 50% -30°C (-22°F) -35°C (-31°F) Liters 11.5 Pressure kPa (psi) 138 (20) 135-155 (19-22)

Engine Cooling – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-3 303-03A-3 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma DESCRIPTION AND OPERATION Engine Cooling Vehicles with 2.2L Duratorq-TDCi (Puma) diesel engine 1 5 E129230 Item Description 1 Radiator 2 Coolant expansion tank 3 Thermostat housing 2 3 4 Item Description 4 Coolant pump 5 Cooling fan motor and shroud CAUTION: If the coolant concentration is insufficient, low temperature protection and corrosion resistance will be inadequate.

Engine Cooling – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-4 303-03A-4 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma DESCRIPTION AND OPERATION NOTE: Providing the coolant has not been contaminated with other fluids or foreign material, the robust corrosion resistance properties of this coolant means that it can be reused after changing an aluminium cooling system component. The concentration should always be checked and maintained within specification. Coolant concentration should be checked through the neck of the coolant expansion tank with a hydrometer. The acceptable range of specific gravity (sg) must be maintained. The coolant used is an orange colored Motorcraft Super Plus 2000 engine coolant. This is a non silicated organic acid technology (OAT) coolant that must not be mixed with other coolant types. For cooling system top up, only use coolant which meets the correct specification.

Engine Cooling – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-5 303-03A-5 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma GENERAL PROCEDURES 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(24 122 0) Draining WARNING: When releasing the cooling system pressure, cover the coolant expansion tank cap with a thick cloth. 1. Release the cooling system pressure by slowly turning the coolant expansion tank cap between 2 and 3 turns. x3 E139585 2. E139584 3. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 4. x4 E130132 5. Remove the radiator drain plug and drain the coolant. E139586 6. Install the radiator drain plug. 7. Lower the vehicle. Filling 1. Refill the coolant to the expansion tank to maximum line (+15mm). Bleeding CAUTION: The fluid level must remain between the MAX and MIN marks. 1. Run the engine for 5 minutes at idle rpm.

Engine Cooling – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-6 303-03A-6 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma GENERAL PROCEDURES 2. Install the coolant expansion tank cap. 3. Run the engine speed to 2500 RPM and maintain it for approximately 15 minutes. 4. Run the engine for 5minutes at idle rpm. 5. Switch the engine off. 6. Check the cooling system for leaks. 7. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 8. Torque: 30 Nm x4 E130132 9. Lower the vehicle. 10.Allow the engine to cool and maintain close to room temperature. 11. Fill the coolant to the expansion tank max fill line, if required.

Engine Cooling – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-7 303-03A-7 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Thermostat(24 454 0) Removal NOTE: Removal steps in this procedure may contain installation details. 1. Drain the cooling system. 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). 2. Torque: 10 Nm x3 E129919 3. E129920 Installation 1. NOTE: Inspect the thermostat housing cover O-ring seal. Install a new O-ring seal if necessary. To install, reverse the removal procedure. 2. Bleed the cooling system. 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).

Engine Cooling – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-8 303-03A-8 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Thermostat Housing(24 001 0) Removal NOTE: Removal steps in this procedure may contain installation details. 1. Drain the cooling system. 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). 2. E129890 3. E129891 4. Torque: 23 Nm 4 2 1 3 E129893 Installation 1. To install, reverse the removal procedure. 2. Bleed the cooling system. 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).

Engine Cooling – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A- 303-03A- Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Coolant Pump(24 404 0) Removal NOTE: Removal steps in this procedure may contain installation details. 1. Drain the cooling system. 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 - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, General Procedures). 2. Refer to: Accessory Drive Belt - 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 (303-05 Accessory Drive - 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). 3. Torque: 14 Nm E129991 4. E129992 5. E129993 6. 2. Torque: 23 Nm 4. Torque: 23 Nm 4 x2 3 2 1 E133605

Engine Cooling – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-10 303-03A-10 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 7. NOTE: Use care when cleaning the water pump gasket mating surfaces. Gouges in the aluminum could form leak paths. E133604 Installation 1. To install, reverse the removal procedure. 2. Bleed the cooling system. 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 - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, General Procedures).

Engine Cooling – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-11 303-03A-11 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Radiator(24 254 0) Removal NOTE: Removal steps in this procedure may contain installation details. E127554 3. E133200 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. x3 4. NOTE: Take extra care not to damage the A/C refrigerant filling pipe. E133201

Engine Cooling – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-12 303-03A-12 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 5. Torque: 20 Nm 1 x2 2 E130161 6. Lift the A/C condenser off the supports and move the A/C condenser toward the front of the vehicle and securely strap the A/C condenser on the grill support. Torque: 7 Nm E129801 7. NOTE: Radiator insulators are to be reused unless damaged. NOTE: Take extra care not to damage the radiator during removal. E130182 Installation 1. NOTE: Make sure that no components catch when installing the radiator. To install, reverse the removal procedure.

Engine Cooling – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-13 303-03A-13 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Cooling Fan Motor and Shroud(24 222 0) Special Tool(s) 303-1196 Holding Wrench, Pulley E62783 303-378 Wrench, Fan Hub 24002 Removal NOTE: Removal steps in this procedure may contain installation details. 1. Drain the cooling system. 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). 2. E130127 3. E130128 4. E130129 5. E130130

Engine Cooling – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-14 303-03A-14 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION 6. Special Tool(s): 303-378, 303-1196 Torque: 105 Nm 303-378 303-1196 E130131 E133199 Installation 1. To install, reverse the removal procedure. 2. Bleed the cooling system. 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). 7. Remove the fan and position it inside the shroud. Lift the fan and shroud together and remove from the vehicle.

Engine Cooling – 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 303-03A-15 303-03A-15 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma REMOVAL AND INSTALLATION Coolant Outlet Connector Removal NOTE: Removal steps in this procedure may contain installation details. 1. Drain the cooling system. 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 - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, General Procedures). 2. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 3. Refer to: Accessory Drive Belt - 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 (303-05 Accessory Drive - 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). 4. NOTE: Make sure that these components are installed to the noted removal position. NOTE: The gasket is to be reused unless damaged. 1. Torque: 23 Nm 2. Torque: 48 Nm 2 x2 2 1 E133596 Installation 1. To install, reverse the removal procedure. 2. Bleed the cooling system. 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 - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, General Procedures).