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1 Page 1 of C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma Ranger Assembly Procedure revision date: 07/21/2016 Special Tool(s) / General Equipment Engine Base Part Number: 6L (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge Holding Fixture, Dial Indicator Gauge Dial Indicator Gauge (Metric) Timing Tool Timing Tool, Crankshaft Locking Tool, Flywheel Separator, Oil Pan Holding Fixture, Dial Indicator Gauge (Cylinder Liner Protrusion) Aligner, Engine Front Cover Timing Tool, Crankshaft Piston Ring Compressor Materials Name Silicone Sealant Specification WSE-M4G323-A4 Engine Oil - SAE 5W-30 WSS-M2C913-C 1. NOTE: The cylinder block oil filter must be installed flush to 0.04 inch (1 mm) underflush. Install the cylinder block oil filter.

Page 2 of 23 2. NOTE: The piston cooling nozzles must be fully inserted before installing the bolt. Install the piston cooling nozzles and new bolts.

NOTE: Verify that the hole in the bearings aligns with the oil gallery in the cylinder block. Install the crankshaft upper bearings.

2 Page 2 of NOTE: The piston cooling nozzles must be fully inserted before installing the bolt. Install the piston cooling nozzles and new bolts. Torque: 10 Nm 3. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly. NOTE: Verify that the hole in the bearings aligns with the oil gallery in the cylinder block. Install the crankshaft upper bearings. Lubricate with clean engine oil Material: Engine Oil - SAE 5W-30 (WSS-M2C913-C) 4. Lubricate with clean engine oil and install the crankshaft. Material: Engine Oil - SAE 5W-30 (WSS-M2C913-C)

Page 3 of 23 5. NOTE: Make sure that these components are installed to the noted removal position. Material: Engine Oil - SAE 5W-30 (WSS-M2C913-C) 6.

Torque: Stage 1: 6 Nm Stage 2: 15 Nm Stage 3: 20 Nm Stage 4: 35 Nm Stage 5: 80 Nm Stage 6: 90 7. Using the special tool, check the crankshaft end play.

3 Page 3 of NOTE: Make sure that these components are installed to the noted removal position. Material: Engine Oil - SAE 5W-30 (WSS-M2C913-C) 6. NOTE: Make sure that these components are installed to the noted removal position. NOTE: Install all the bolts finger tight before final tightening. Torque: Stage 1: 6 Nm Stage 2: 15 Nm Stage 3: 20 Nm Stage 4: 35 Nm Stage 5: 80 Nm Stage 6: Using the special tool, check the crankshaft end play. Refer to: Specifications - Vehicles Built From: 17-August-2015 (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Specifications). Use Special Service Tool: (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

Page 4 of 23 8. If necessary, position the crankshaft sprocket washer. 9.

NOTE: Care must be taken not to damage the piston cooling nozzles while doing the measuring.

4 Page 4 of If necessary, position the crankshaft sprocket washer. 9. If necessary, install the crankshaft sprocket and bolt. Torque: 36 Nm 10. NOTE: Care must be taken not to damage the piston cooling nozzles while doing the measuring. NOTE: Failure to have the crankshaft connecting rod journal at TDC (top dead center) may result in the incorrect selection of connecting rod. Position the crankshaft connecting rod journal at TDC for the cylinder that is being measured. Using a commercially available Depth Gauge, measure the crankshaft connecting rod journal to cylinder block deck measurement on all cylinder bores.

Page 5 of 23 11. Select the appropriate connecting rod grade using the crank pin to cylinder head face value 'X' from the Connecting Rod Grade Selection table.

Refer to: Piston (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Disassembly and Assembly of Subassemblies). 13.

5 Page 5 of Select the appropriate connecting rod grade using the crank pin to cylinder head face value 'X' from the Connecting Rod Grade Selection table. Refer to: Specifications - Vehicles Built From: 17-August-2015 (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Specifications). 12. If any of the connecting rods need to be replaced. Refer to: Piston (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Disassembly and Assembly of Subassemblies). 13. NOTE: Make sure that these components are installed to the noted removal position. Use the General Equipment: Piston Ring Compressor Material: Engine Oil - SAE 5W-30 (WSS-M2C913-C) 14. NOTE: If reusing the connecting rod bearings, install them in their original positions and orientation as noted during disassembly. Install the connecting rod bearings. Lubricate with clean engine oil. Material: Engine Oil - SAE 5W-30 (WSS-M2C913-C)

Page 6 of 23 15. NOTE: Make sure that these components are installed to the noted removal position. Material: Engine Oil - SAE 5W-30 (WSS-M2C913-C) 16.

Torque: Stage 1: 8 Nm Stage 2: 25 Nm Stage 3: 60 Nm Stage 4: 90 17. Using the special tool, check the piston protrusion. If not within specifications, repeat the connecting rod length calculation.

6 Page 6 of NOTE: Make sure that these components are installed to the noted removal position. Material: Engine Oil - SAE 5W-30 (WSS-M2C913-C) 16. NOTE: Make sure that these components are installed to the noted removal position. NOTE: Install all the bolts finger tight before final tightening. Torque: Stage 1: 8 Nm Stage 2: 25 Nm Stage 3: 60 Nm Stage 4: Using the special tool, check the piston protrusion. If not within specifications, repeat the connecting rod length calculation. Refer to: Specifications - Vehicles Built Up To: 16-August-2015 (303-01B Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/2.2L Duratorq-TDCi (118kW/160PS) - Puma, Specifications). Use Special Service Tool: (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge. 18.

Page 7 of 23 19. NOTE: Only tighten the bolts finger tight at this stage. 20.

The rear clearance does not exceed 0.05 mm gap.

Using a straight edge, align the side surface of the ladderframe with the side surface of the engine block.

7 Page 7 of NOTE: Only tighten the bolts finger tight at this stage. 20. Using a straight edge, align the rear surface of the ladderframe with the rear surface of the engine block. The rear clearance does not exceed 0.05 mm gap. Use Special Service Tool: Holding Fixture, Dial Indicator Gauge (Cylinder Liner Protrusion). 21. Using a straight edge, align the side surface of the ladderframe with the side surface of the engine block. The side clearance does not exceed 0.01mm overlap. Use Special Service Tool: Holding Fixture, Dial Indicator Gauge (Cylinder Liner Protrusion). 22. Torque: Stage 1: 6 Nm Stage 2: 23 Nm

Page 8 of 23 23. NOTE: Only tighten the bolts finger tight at this stage. 24.

Use Special Service Tool: 205-044 Holding Fixture, Dial Indicator Gauge., 205-069 Dial Indicator Gauge (Metric). 25.

8 Page 8 of NOTE: Only tighten the bolts finger tight at this stage. 24. Take a reference measurement from the front face of the crankshaft sprocket. Use Special Service Tool: Holding Fixture, Dial Indicator Gauge., Dial Indicator Gauge (Metric). 25. Take measurements at two different points on the oil pump sprocket and align the oil pump sprocket. Use Special Service Tool: Holding Fixture, Dial Indicator Gauge., Dial Indicator Gauge (Metric). 26. Torque: 1: 10 Nm 2: 13 Nm

crankshaft rear seal is fully installed. Failure to follow this instruction may result in damage to the vehicle.

9 Page 9 of Torque: 10 Nm 28. NOTE: A new crankshaft rear seal carrier is supplied with an alignment sleeve that must not be removed until the crankshaft rear seal is fully installed. Failure to follow this instruction may result in damage to the vehicle. Clean the area on the engine before installing a new crankshaft rear seal carrier. Check the two foam pads are located as shown on the ladder frame gasket. 29. Material: Engine Oil - SAE 5W-30 (WSS-M2C913-C)

Page 10 of 23 30. NOTE: Install new crankshaft rear seal carrier with in five minutes after applying the recomended sealent.

NOTE: Do not add any more than the specified quantity of sealant or add the sealant anywhere other than the area shown.

Material: Silicone Sealant (WSE-M4G323-A4) 31.

10 Page 10 of NOTE: Install new crankshaft rear seal carrier with in five minutes after applying the recomended sealent. Failure to follow this instruction may result in damage to the vehicle. NOTE: Do not add any more than the specified quantity of sealant or add the sealant anywhere other than the area shown. NOTE: If the foam pads are not present on inspection, fill the square areas shown with 75% of sealant. Material: Silicone Sealant (WSE-M4G323-A4) 31. NOTICE: A new crankshaft rear seal carrier is supplied with an alignment sleeve that must not be removed until the crankshaft rear seal is fully installed. Failure to follow this instruction may result in damage to the vehicle. NOTE: Initially hand tighten the fasteners. 32. NOTE: New crankshaft rear seal carriers are supplied with an alignment sleeve which must be removed after installation. Torque:

Page 11 of 23 : Stage 1: 5 Nm Stage 2: 10 Nm 33.

before installing the flywheel bolts. Initially hand tighten the fasteners. 34.

11 Page 11 of 23 : Stage 1: 5 Nm Stage 2: 10 Nm 33. NOTE: Make sure that the flywheel is in full contact with the crankshaft flange before installing the flywheel bolts. Initially hand tighten the fasteners. 34. NOTICE: Make sure that the flywheel is in full contact with the crankshaft flange before installing the flywheel bolts. Use Special Service Tool: Locking Tool, Flywheel. Torque: Stage 1: 25 Nm Stage 2: 40 Nm Stage 3: Use Special Service Tool: Timing Tool, Crankshaft.

Page 12 of 23 Vehicles with manual transmission 36.

NOTE: Make sure that the special tool is located in the

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

12 Page 12 of 23 Vehicles with manual transmission 36. Initially hand tighten the fasteners. 37. NOTE: Make sure that the special tool is located in the flywheel timing slot. Use Special Service Tool: Timing Tool, Crankshaft. 38. Tighten bolts before removing tool. Remove Special Service Tool: Timing Tool, Crankshaft. Torque: 20 Nm 39. Torque: 8 Nm

Page 13 of 23 Vehicles with automatic transmission

Use Special Service Tool: 303-698 Timing Tool,

NOTE: Make sure that the special tool is located

Use Special Service Tool: 303-1562 Timing Tool. 42.

13 Page 13 of 23 Vehicles with automatic transmission 40. Initially hand tighten the fasteners. Use Special Service Tool: Timing Tool, Crankshaft. 41. NOTE: Make sure that the special tool is located in the flexplate timing slot. Use Special Service Tool: Timing Tool. 42. Tighten bolts before removing tool. Remove Special Service Tool: Timing Tool. Torque: 20 Nm 43. Torque: 8 Nm

surfaces. These tools cause scratches and gouges that make leak paths.

NOTE: Measure the piston protrusion of each cylinder at top dead center (TDC).

14 Page 14 of 23 All vehicles 44. WARNING: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket. 45. NOTE: Measure the piston protrusion of each cylinder at top dead center (TDC). Measure the distance between the piston crown and the cylinder block at the points indicated. 46. NOTE: The largest measurement determines the choice of the cylinder head gasket. Using the special tools, measure the piston protrusion. Use Special Service Tool: (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

Page 15 of 23 47. Determine the cylinder head gasket. Refer to: Specifications - Vehicles Built From: 17-August-2015 (303-01C Engine - 3.

NOTICE: Make sure that new cylinder head bolts are installed.

15 Page 15 of Determine the cylinder head gasket. Refer to: Specifications - Vehicles Built From: 17-August-2015 (303-01C Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Specifications). 48. NOTE: Make sure that a new component is installed NOTICE: Make sure that new cylinder head bolts are installed. Torque: Stage 1: 1-12: 10 Nm Stage 2: 13-22: 5 Nm Stage 3: 1-12: 20 Nm Stage 4: 13-22: 10 Nm Stage 5: 1-12: 35 Nm Stage 6: 13-22: 20 Nm Stage 7: 1-12: 45 Nm Stage 8: 13-22: 26 Nm Stage 9: 1-12: 90 Stage 10: 13-22: 90 Stage 11: 1-12: 90 Stage 12: 13-22: 90

Torque: Stage 1: 1-26: 7 Nm Stage 2: 27-28: 4 Nm

16 Page 16 of Material: Silicone Sealant (WSE-M4G323-A4) 52. Torque: Stage 1: 1-26: 7 Nm Stage 2: 27-28: 4 Nm Stage 3: 1-26: 15 Nm Stage 4: 27-28: 6 Nm Stage 5: 1-26: 23 Nm Stage 6: 27-28: 10 Nm 53. Torque: Stage 1: 5 Nm Stage 2: 8 Nm Stage 3: 10 Nm Stage 4: Tighten the fuel injection pump bracket nut and bolts. Tighten in the sequence shown. Torque: Stage 1: 22 Nm Stage 2: 10 Nm Stage 3: 22 Nm

17 Page 17 of Torque: 45 Nm Install Special Service Tool: Timing Tool, Crankshaft. 58. NOTE: Make sure that the installation marks are aligned. Use the General Equipment: 6 mm Drill Bit Torque: Stage 1: 12 Nm Stage 2: 24 Nm

18 Page 18 of NOTE: Make sure that new bolts are installed. Torque: 1: 14 Nm 2: 31 Nm 3: 15 Nm 60. NOTE: Make sure that a new component is installed. Torque: 15 Nm 61. Remove Special Service Tool: Timing Tool, Crankshaft.

Page 19 of 23 62. Rotate the engine two revolutions. 63. Install Special Service Tool: 303-1587 Timing Tool, Crankshaft. 64.

19 Page 19 of Rotate the engine two revolutions. 63. Install Special Service Tool: Timing Tool, Crankshaft. 64. Check the position of the timing marks and correct if necessary. 65. Remove the 6 mm drill bits. 66. Remove Special Service Tool: Timing Tool, Crankshaft. 67.

NOTE: The component must be installed within 5 minutes

20 Page 20 of Torque: stage 1: 4 Nm stage 2: 10 Nm 69. NOTE: Make sure that a new component is installed. Install the new engine front cover gasket. 70. 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 (WSE-M4G323-A4)

Use Special Service Tool: 303-428 Separator, Oil Pan. 73.

21 Page 21 of Use Special Service Tool: Aligner, Engine Front Cover. Torque: Stage 1: 5 Nm Stage 2: 10 Nm 72. NOTE: Do not damage the mating faces. Use Special Service Tool: Separator, Oil Pan. 73. NOTICE: Install the oil pan within five minutes of applying the sealer. NOTE: Do not damage the mating faces. Material: Silicone Sealant (WSE-M4G323-A4)

22 Page 22 of Torque: Stage 1: 6 Nm Stage 2: 13 Nm 75. NOTE: The seal is to be reused unless damaged. Torque: 35 Nm 76. Refer to: Engine Accessories ( Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma). Copyright 2017 Ford Motor Company

23 Page 23 of 23

IN-VEHICLE REPAIR. Engine Front Cover

IN-VEHICLE REPAIR. Engine Front Cover 303-01A-1 IN-VEHICLE REPAIR Engine Front Cover Material Item Specification 303-01A-1 Special Tool(s) SAE 5W-20 Premium WSS-M2C930-A Synthetic Blend Motor Oil Alignment Plate, Camshaft XO-5W20-QSP (in Canada