3.2 Diesel. Distribución. Puesta A Punto.

303-01C-1 Engine — 3.
2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-1

.
SECTION 303-01C Engine — 3.2L Duratorq-TDCi (148kW/200PS) - Puma

VEHICLE APPLICATION: 2011.50 Ranger
CONTENTS PAGE
SPECIFICATIONS
Specifications...................................................................................................................... 303-01C-3
Engine Data.................................................................................................................... 303-01C-3
Engine Oil Capacity........................................................................................................ 303-01C-3
Cylinder Block Dimensions............................................................................................. 303-01C-3
Piston Dimensions.......................................................................................................... 303-01C-3
Crankshaft Dimensions................................................................................................... 303-01C-4
Connecting Rod Dimensions.......................................................................................... 303-01C-4
Piston Pin Dimensions ................................................................................................... 303-01C-4
Camshaft Dimensions..................................................................................................... 303-01C-4
Valve Dimensions........................................................................................................... 303-01C-4
Cylinder Head Dimensions............................................................................................. 303-01C-4
Oil Pressure Specifications............................................................................................. 303-01C-5
DESCRIPTION AND OPERATION

Engine (Overview).............................................................................................................. 303-01C-6
General View...................................................................................................................... 303-01C-6
Engine overview ............................................................................................................ 303-01C-8
Power and torque curves ............................................................................................... 303-01C-8
Engine type identification................................................................................................ 303-01C-9
Cylinder head.................................................................................................................. 303-01C-9
Electronic turbocharger guide vane adjustment............................................................. 303-01C-11
Oil level/temperature sensor........................................................................................... 303-01C-11
Service instruction.......................................................................................................... 303-01C-11
Engine (Component Location)............................................................................................ 303-01C-12
REMOVAL AND INSTALLATION

Intake Manifold............................................................................................... (21 183 0) 303-01C-15
Exhaust Manifold............................................................................................ (21 187 0) 303-01C-18
Valve Cover.................................................................................................... (21 141 0) 303-01C-20
Camshafts...................................................................................................... (21 284 0) 303-01C-22
Valves................................................................................................................................. 303-01C-26
Valve Springs...................................................................................................................... 303-01C-28
Valve Stem Seals........................................................................................... (21 238 0) 303-01C-30
Timing Cover.................................................................................................. (21 146 0) 303-01C-31
Cylinder Head................................................................................................. (21 163 0) 303-01C-36
Oil Pan............................................................................................................ (21 154 0) 303-01C-39
Oil Pump......................................................................................................... (21 714 0) 303-01C-43
Engine Front Seal............................................................................................................... 303-01C-45
Crankshaft Rear Seal..................................................................................... (21 468 4) 303-01C-48
303-01C-2 Engine — 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-2
.
REMOVAL
Engine — Vehicles With: 6-Speed Manual Transmission - MT82.................. (21 132 0;
21 132 6;
21 132 7) 303-01C-51
Engine — Vehicles With: 6-Speed Automatic Transaxle - 6R80.................... (21 132 0;
21 132 6;
21 132 7) 303-01C-60
Engine Accessories........................................................................................ (21 139 4) 303-01C-70
DISASSEMBLY
Engine............................................................................................................ (21 134 8) 303-01C-83
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Cylinder Head................................................................................................. (21 165 6) 303-01C-89
ASSEMBLY
Engine............................................................................................................ (21 134 8) 303-01C-90
INSTALLATION
Engine — Vehicles With: 6-Speed Manual Transmission - MT82.................. (21 132 0;
21 132 6;
21 132 7) 303-01C-103
Engine — Vehicles With: 6-Speed Automatic Transaxle - 6R80.................... (21 132 0;
21 132 6;
21 132 7) 303-01C-112
Engine Accessories........................................................................................ (21 139 4) 303-01C-122
SPECIFICATIONS
Engine Data
Description
Code SAFA
Firing order 1-2-4-5-3
Bore diameter 89.9 mm
Stroke 100.76 mm
Displacement 3198 cc
Compression ratio 17.5:1
Power output at 3500 rpm 147 kW (200 PS)
Torque between 2000 to 2500 rpm 470 Nm
Idle speed 800 +/- 50 rpm
Maximum oil consumption 0.1L / 1000 Km
Engine Oil Capacity

Description Liters
Initial fill including oil filter 12,6
Service fill including oil filter 11,4
Service fill without oil filter 11,0
Cylinder Block Dimensions

Description mm
Cylinder bore diameter — Class 1 89.900 - 89.910
Main bearing shells 1 to 5 inner diameter — bearings installed 64.994 - 65.022
Main bearing shell 6 inner diameter — bearings installed 69.994- 70.022
Main bearings 1 to 5 radial clearance 0.024 - 0.072
Main bearing 6 radial clearance 0.024 - 0.072
Main bearings 1 to 5 parent bore diameter — vertical measurement 69.504 - 64.520
Main bearing 6 parent bore diameter — vertical measurement 74.504 - 74.520
Main bearings 1 to 5 parent bore diameter — horizontal measurement 69.502 - 69.525
Main bearing 6 parent bore diameter — horizontal measurement 74.502 - 74.525
Piston Dimensions
Description mm
Piston diameter — Class 1 89.84 - 89.85
Piston clearance in cylinder 0.05 - 0.07
Piston ring end gaps
2011.50 Ranger
SPECIFICATIONS
Description mm
— upper compression ring 0.25 - 0.40
— lower compression ring 0.50 - 0.75
— oil control ring 0.25 - 0.50
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 mm
Main bearing journal end float 0.090 - 0.305
Main bearing journals 1 to 5 diameter 64.950 - 64.970
Main bearing journal 6 diameter 69.950 - 69.970
Connecting rod bearing journal diameter 52.980 - 53.000
Connecting Rod Dimensions

Description mm
Large end bore diameter 55.996 - 56.016
Small end bore diameter 32.010 - 32.018
Connecting rod bearing shell inner diameter — bearings installed 53.016 - 53.046
Connecting rod bearing radial clearance 0.026 - 0.084
Connecting rod bearing axial clearance 0.100 - 0.320
Piston Pin Dimensions

Description mm
Piston pin length 73.95
Piston pin diameter 31.998 - 32.002
Piston pin slide clearance 0.008 - 0.018
Camshaft Dimensions
Description mm
Camshaft end float 0.014 - 0.200
Camshaft bearing journal diameter 26.440 - 26.465
Camshaft bearing clearance — radial measurement 0.04 - 0.09
Valve Dimensions
Description mm
Valve stem to valve guide clearance — intake valve 0.0625 - 0.0275
Valve stem to valve guide clearance — exhaust valve 0.0725 - 0.0375
Cylinder Head Dimensions

Description mm
Maximum distortion — measured longitudinally and diagonally 0.10
2011.50 Ranger
SPECIFICATIONS
Description mm
Peak to valley height of mating surface 0.02
Cylinder head gasket thickness
Piston protrusion of 0.310 - 0.400 mm 1.1 (one hole/tooth)
Piston protrusion of 0.401 - 0.450 mm 1.15 (two holes/teeth)
Piston protrusion of 0.451 - 0.500 mm 1.2 (three holes/teeth)
Oil Pressure Specifications

Description bar
Minimum oil pressure at idle speed 1.25
Minimum oil pressure at 2000 rpm 2.5
Lubricants, Fluids, Sealers and Adhesives

Item Specification
Ford Formula E SAE 5W-30 engine oil WSS-M2C913-B
Sealer — oil pan, camshaft carrier and engine front cover WSE-M4G323-A4
2011.50 Ranger
Engine – Overview
General View • The upper part houses the rocker arm frame
with the roller rocker arms. The hydraulic valve
• The 3.2L Duratorq-TDCi (Puma) diesel engine clearance adjustment is integrated in the roller
is a five-cylinder inline engine which delivers a rocker arms.
power of 147kW (200 PS). • The camshafts and the fuel injection pump are
• The engine is additionally equipped with an oil driven by the crankshaft via the timing chain.
level/oil temperature sensor . • The oil pump is located inside the oil pan and
• The cylinder head consists of two parts and is is driven by the crankshaft via a chain.
made of aluminum. Both parts are bolted to NOTE: Cylinder 1 is located on the timing chain
each other. end.
• The lower part contains four valves for each
combustion chamber and the two camshafts.
2011.50 Ranger
E131231
2011.50 Ranger
Engine overview Item Description
1 Oil pan
6 2 Oil pan extension
5
3 Cylinder block
4 Cylinder head lower part
4 5 Cylinder head upper part
6 Valve cover
3
Power and torque curves
E131900
1 2
A C
E94909
2011.50 Ranger
Item Description Item Description
A Torque (Nm) 1 Torque curve for the 147 kW engine (200
PS)
B Engine speed (rpm)
2 Power curve for the 147 kW engine (200
C Power (kW)
PS)
Engine type identification
XXXXXXXX
XXXXXX
E131233
Item Description
1 Engine code
2 Engine serial number
On the 3.2L engine the engine code (4 digits) and If the engine or cylinder block is changed, the
the engine serial number (2 letters for the year and vehicle identification number must be stamped in
month and 5 figures for the serial number) are the indicated location.
stamped in the cylinder block on the exhaust side
(in line with cylinder no. 5).
Cylinder head
2011.50 Ranger
E94935

1 Cylinder head lower part 4 Camshafts
2 Cylinder head upper part 5 Roller rocker arms with hydraulic valve
clearance adjustment
3 Rocker arm frame
2011.50 Ranger
Electronic turbocharger guide vane operating conditions) and displays it in the
adjustment 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
E131898 level ground.
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
2011.50 Ranger
Engine – Component Location
E131231
2011.50 Ranger
7
6
5 8
10
1
11
2
3
12 13
4
E131232

1 Turbocharger 7 Valve cover
2 Exhaust manifold 8 Thermostat
3 Oil pan 9 Coolant pump
4 Flywheel 10 Fuel pump
5 Vacuum pump 11 Intake manifold
6 Fuel rail 12 Oil cooler
13 EGR valve
2011.50 Ranger
XXXXXXXX
XXXXXX
E131233
Item Description
1 Engine code
2 Engine serial number
2011.50 Ranger
Intake Manifold(21 183 0)

4.
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 E129866
stops before commencing any repair to the
fuel injection system. Failure to follow this 5.
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.
E130889
E129579
2011.50 Ranger
6. Torque: 11 Nm 9.
x2
E130890 E130892
7. Refer to: Exhaust Gas Recirculation (EGR) 10.

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, Removal and Installation).
8. 2. Torque: 10 Nm
3. Torque: 15 Nm
E130893
1
11.
x4
3
2
E130891
E129686
2011.50 Ranger
12. NOTE: Replace the o-ring, if necessary.
NOTE: The gasket is to be reused unless
damaged.
Torque: 15 Nm
1
x1
E130894
Installation
1. To install, reverse the removal procedure.
2011.50 Ranger
Exhaust Manifold(21 187 0)

4. Refer to: Turbocharger - 3.2L Duratorq-TDCi
Removal (148kW/200PS) - Puma, LHD 4WD/LHD RWD
(303-04 Fuel Charging and Controls -
NOTE: Removal steps in this procedure may Turbocharger, Removal and Installation).
contain installation details. Refer to: Turbocharger - 3.2L Duratorq-TDCi
(148kW/200PS) - Puma, RHD 4WD/RHD
1. Refer to: Health and Safety Precautions (100-00 RWD (303-04 Fuel Charging and Controls -
General Information, Description and Turbocharger, Removal and Installation).
Operation). Refer to: Generator - 3.2L Duratorq-TDCi
(148kW/200PS) - Puma (414-02 Generator
2. Refer to: Battery Disconnect and Connect and Regulator, Removal and Installation).
General Procedures). 5.
3.
E132022
E131104
6. 1. Torque: 9 Nm
2. Torque: 22 Nm
3. Torque: 25 Nm
1 2
x5
x2
x2
3
E131140
2011.50 Ranger
7. Refer to: Lifting (100-02 Jacking and Lifting, NOTE: The gasket is to be reused unless
Description and Operation). damaged.
8. Remove front RH side wheel only.
Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
9. Torque: 10 Nm
E131142
Installation
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
x1
2
0
x3
E131141
11. CAUTION: Make sure that new studs are

installed.
2011.50 Ranger
Valve Cover(21 141 0)

3. Refer to: Fuel Injectors (303-04 Fuel Charging
Removal and Controls - 3.2L Duratorq-TDCi
(148kW/200PS) - Puma, Removal and
NOTE: Removal steps in this procedure may Installation).
contain installation details. 4. 1. Torque:
• Stage 1: 5 Nm
1. Refer to: Health and Safety Precautions (100-00 • Stage 2: 35 Nm
General Information, Description and 2. Torque: 10 Nm
Operation).
Refer to: Battery Disconnect and Connect
2. x3
2
1
E133633
5. Torque: 10 Nm
E131104
x9
x3
E131105
2011.50 Ranger
6. NOTE: The gasket is to be reused unless
damaged.
E134582
Installation
2011.50 Ranger
Camshafts(21 284 0)
Special Tool(s) / General Equipment 1. Refer to: Fuel Rail (303-04 Fuel Charging and
100-010 Controls - 3.2L Duratorq-TDCi (148kW/200PS)
Remover, O-Ring Seal - Puma, Removal and Installation).
Refer to: Valve Cover (303-01 Engine - 3.2L
Duratorq-TDCi (148kW/200PS) - Puma,
Removal and Installation).
17063 Refer to: Timing Cover (303-01 Engine - 3.2L
303-1562 Refer to: Brake Vacuum Pump - 3.2L
Timing Tool Duratorq-TDCi (148kW/200PS) - Puma
(206-07 Power Brake Actuation, Removal and
Installation).
2. Special Tool(s): 100-010
E131853 General Equipment: 2 mm Punch
100-010
2 mm Punch
6 mm Drill Bit 2
1
Removal 3
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 E87423
are always present and may ignite. Failure
to follow these instructions may result in
personal injury. 3. General Equipment: 2 mm Punch
E87424
2011.50 Ranger
4. Installation
1. NOTE: Clean the mating faces of the camshaft
carrier and the cylinder head.
x2
Torque:
x3
x3
• Bolts 1 to 26
• Stage 1: 3,5 Nm
x2
• Stage 2: 15 Nm
• Stage 3: 23 Nm
• Bolts 27 and 28
• Stage 1: 3,5 Nm
• Stage 2: 7,5 Nm
x2
• Stage 3: 10 Nm
26 22 14 8 6 16 24
18 10 4 2 12 20
E95464
17 9 3 1 11 19
5.
25 21 13 7 5 15 23
27
28
E94486
x12
11 7 3 1 5 9
2. NOTE: Make sure that the rocker arms do not

separate.
Torque:
12 8 4 2 6 10 • Stage 1: 10 Nm
• Stage 2: 30°
E94096
6.
x12
11 7 3 1 5 9
x2
12 8 4 2 6 10
E94096
E94111
2011.50 Ranger
3. Special Tool(s): 303-1562 6. Torque:
• 1 15 Nm
303-1562 • 2 40 Nm
• 3 40 Nm
x2 1
x2 1
E138698 2
4. NOTE: Make sure that the installation marks

are aligned.
General Equipment: 6 mm Drill Bit
Torque: 33 Nm x2 3
E95442
7. NOTE: Make sure that a new component is

installed.
x3
x3
Torque: 15 Nm
x2
E95422
5. Remove the 6 mm drill bit. E75760
8. Remove the Special Tool(s): 303-1562
303-1562
E138698
9. Rotate the engine two revolutions.
2011.50 Ranger
10. Special Tool(s): 303-1562 14. Refer to: Brake Vacuum Pump - 3.2L
Duratorq-TDCi (148kW/200PS) - Puma
303-1562 (206-07 Power Brake Actuation, Removal and
Installation).
Refer to: Timing Cover (303-01 Engine - 3.2L
Refer to: Valve Cover (303-01 Engine - 3.2L
Refer to: Fuel Rail (303-04 Fuel Charging and
Controls - 3.2L Duratorq-TDCi (148kW/200PS)
E138698 - Puma, Removal and Installation).
11. Check the valve timing by inserting the drill bits.

If the drill bits cannot be inserted repeat the
timing steps.
General Equipment: 6 mm Drill Bit
E95424
12. Remove the 6 mm drill bits.

303-1562
E138698
2011.50 Ranger
Valves
Special Tool(s) Special Tool(s)
303-060 303-060-07
Compressor, Valve Spring Adapter for 303-060
2102407
21024
303-060-05 303-362
Adapter for 303-060 Installer, Valve Stem Collets
21156
2102405
Removal
NOTE: Removal steps in this procedure may 3. Special Tool(s): 303-060, 303-060-05,
contain installation details. 303-060-07, 303-362
1. Refer to: Cylinder Head (303-01 Engine - 3.2L
Duratorq-TDCi (148kW/200PS) - Puma, 303-060
2. NOTE: Position a socket on the valve spring
seat and gently strike it with a hammer.
303-362
303-060-05
303-060-07
E95039
ELE0015706
2011.50 Ranger
4.
E139000
Installation
2011.50 Ranger
Valve Springs
303-060 303-060-07
Compressor, Valve Spring Adapter for 303-060
2102407
21024
303-060-05 303-362
Adapter for 303-060 Installer, Valve Stem Collets
21156
2102405
Removal
1. Refer to: Valve Cover (303-01 Engine - 3.2L 4. Special Tool(s): 303-060, 303-060-05,
Duratorq-TDCi (148kW/200PS) - Puma, 303-060-07, 303-362
2.
303-060
x12
11 7 3 1 5 9
303-362
12 8 4 2 6 10 303-060-05
E94096
303-060-07
3. Position the appropriate piston at top dead E95544
center (TDC).
2011.50 Ranger
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
E95544
2. Torque:
• Stage 1: 10 Nm
• Stage 2: 30°
x12
11 7 3 1 5 9
12 8 4 2 6 10
E94096
3. Refer to: Valve Cover (303-01 Engine - 3.2L

2011.50 Ranger
Valve Stem Seals(21 238 0)

Special Tool(s)
303-508
Pliers, Valve Stem Seal
21211
Removal
1. Refer to: Valve Springs (303-01 Engine - 3.2L
303-508
E95598
Installation
2011.50 Ranger
Timing Cover(21 146 0)

Special Tool(s) 1. Refer to: Battery Disconnect and Connect
303-428 (414-01 Battery, Mounting and Cables,
Separator, Oil Pan General Procedures).
2. Refer to: Cooling Fan Motor and Shroud (303-03
Engine Cooling - 3.2L Duratorq-TDCi
21179
Installation).
3. Refer to: Generator - 3.2L Duratorq-TDCi
303-682 (148kW/200PS) - Puma (414-02 Generator
Aligner, Engine Front Cover and Regulator, Removal and Installation).
4. 1. Torque: 35 Nm
2. Torque: 35 Nm
303682
Materials
x2
Name Specification
2
Silicone Sealant LB WSE-M4G323-A4 /
2U7J-M4G323-AA
Removal
NOTE: Removal steps in this procedure may x2
contain installation details. 1
E134536
5. 1. Torque: 48 Nm
2. Torque: 23 Nm
x2 1
E131304
2011.50 Ranger
6. Torque: 48 Nm 11. CAUTION: Cap the power steering line
to prevent fluid loss or dirt ingress.
Torque: 7 Nm
x3
3
2
E134532
7. Refer to: Lifting (100-02 Jacking and Lifting,

Description and Operation).
1
8. Torque: 30 Nm
E133691
x4
12.
E130132
x4
9. NOTE: Remove front RH side wheel only.
Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
10.
E133940
x8
E132537
2011.50 Ranger
13. 1. Torque: 20 Nm 16. 3. Torque: 23 Nm
2. Torque: 20 Nm
3. Torque: 18 Nm
3
x3
1
1
E134534
2 17. Torque: 23 Nm
E134533
14. Torque: 10 Nm 1
E134535
E129991
15.
E129992
2011.50 Ranger
18. Refer to: Engine Front Seal (303-01 Engine - NOTE: Do not damage the mating faces.
3.2L Duratorq-TDCi (148kW/200PS) - Puma, Material: Silicone Sealant LB (WSE-M4G323-A4
Removal and Installation). / 2U7J-M4G323-AA) sealant
2
0
x2
303-428 3mm
1
x2
E131310
E131307
Installation
1. CAUTION: Install the timing cover within
five minutes of applying the sealer.
2011.50 Ranger
2. 1. Special Tool(s): 303-682
Torque: 10 Nm
2. Torque: 14 Nm
0
x2
303-682
2
x2
E131309
2011.50 Ranger
Cylinder Head(21 163 0)

Special Tool(s) 1. Refer to: Intake Manifold (303-01 Engine - 3.2L
205-069 Duratorq-TDCi (148kW/200PS) - Puma,
Dial Indicator Gauge (Metric) Removal and Installation).
Refer to: Brake Vacuum Pump - 3.2L
15046
Installation).
Refer to: Exhaust Gas Recirculation (EGR)
Cooler - 3.2L Duratorq-TDCi (148kW/200PS)
205-070 - Puma (303-08 Engine Emission Control -
Holding Fixture, Dial Indicator 2.2L Duratorq-TDCi (88kW/120PS) -
Gauge Puma/2.2L Duratorq-TDCi (96kW/130PS) -
15022A Refer to: Exhaust Manifold (303-01 Engine -
3.2L Duratorq-TDCi (148kW/200PS) - Puma,
303-432 Removal and Installation).
Holding Fixture, Dial Indicator Refer to: Camshafts (303-01 Engine - 3.2L
Gauge (Cylinder Liner Duratorq-TDCi (148kW/200PS) - Puma,
Protrusion) Removal and Installation).
2.
21183
2
3
x1
Removal 0
x1
2

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
2011.50 Ranger
paths. Use a plastic scraping tool to NOTE: Make sure that a new component is
remove all traces of the head gasket. installed.
E131632 E131635
2. NOTE: Measure the piston protrusion of each 5.

cylinder at top dead center (TDC).
Measure the distance between the piston crown
and the cylinder block at the points indicated.
E131636
6. CAUTION: Make sure that new cylinder

E131633
head bolts are installed.
Torque:
3. NOTE: The largest measurement determines • Bolts 1 to 12: 10 Nm
the choice of the cylinder head gasket. • Bolts 13 to 22: 5 Nm
• Bolts 1 to 12: 20 Nm
Special Tool(s): 205-069, 205-070, 303-432
• Bolts 13 to 22: 10 Nm
205-070
• Bolts 1 to 12: 180°
• Bolts 13 to 22: 25 Nm
303-432
• Bolts 13 to 22: 180°
21 6 18 2 14
10 4
16 7
20
205-069
9
E131634 11
4. NOTE: Note the thickness of the gasket. 22

5 12
17 1 13 3 15 8 19
E131637
2011.50 Ranger
7. Refer to: Camshafts (303-01 Engine - 3.2L
Refer to: Exhaust Manifold (303-01 Engine -
3.2L Duratorq-TDCi (148kW/200PS) - Puma,
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) -
Refer to: Brake Vacuum Pump - 3.2L
Installation).
Refer to: Intake Manifold (303-01 Engine - 3.2L
2011.50 Ranger
Oil Pan(21 154 0)

Special Tool(s) 1. Refer to: Engine Cooling System Health and
303-428 Safety Precautions (100-00 General
Separator, Oil Pan Information, Description and Operation).
21179

Materials
4x4
Name Specification
Silicone Sealant LB WSE-M4G323-A4 / 4. Torque: 30 Nm
2U7J-M4G323-AA
x4
Removal
E130132
5. Torque: 30 Nm
2
x4
E133766
2011.50 Ranger
All vehicles 7. Torque: 35 Nm
6. Torque: 30 Nm
x4
1
x4
x4
x3
2 E130951
8. CAUTION: Take extra care when

handling steering gear rack.
1. Torque: 23 Nm
2. Torque: 150 Nm
E128859
3 1
x2
x2
E133875
9. WARNING: Be prepared to collect

escaping fluids.
2011.50 Ranger
Drain the oil pan into a suitable container. 12. Torque: 10 Nm
Torque: 39 Nm
E130954
E130800
4x4
13.
x1
8
303-428
E130952
11. Torque: 10 Nm
E130955
E130953
2011.50 Ranger
4x2 NOTE: Do not damage the mating faces.
14. Material: Silicone Sealant LB (WSE-M4G323-A4
/ 2U7J-M4G323-AA) sealant
3mm
E133876
E130956
Installation 3. Torque:
1. NOTE: Do not damage the mating faces. • Stage 1: 7 Nm
• Stage 2: 14 Nm
Special Tool(s): 303-428
11
4 12
1 13
9 5
7
10
14
303-428
3
2
16
6
18
17 8
15
E130957
E133924

2. CAUTION: Install the oil pan within five
minutes of applying the sealer. 5. Fill the oil pan with clean engine oil.
Refer to: Specifications (303-01 Engine - 2.5L
Duratec-HE (122kW/165PS) - MI4,
Specifications).
2011.50 Ranger
Oil Pump(21 714 0)

Special Tool(s) 4. WARNING: Be prepared to collect
escaping fluids.
303-705
Aligner, Oil Pump Torque: 13 Nm
303705
Removal
General Information, Description and 1
Operation).
Refer to: Battery Disconnect and Connect
E131540
2. Refer to: Oil Pan (303-01 Engine - 3.2L
Duratorq-TDCi (148kW/200PS) - Puma, 5. NOTE: Do not completely loosen the bolts at
Removal and Installation). this stage.
3. Hand tighten the bolts at this stage.
Torque: 15 Nm
303-705
2
x2
1
303-705
x4
E131541
E131539
2011.50 Ranger
6. Special Tool(s): 303-705 2. NOTE: Hand tighten the bolts at this stage.
303-705
303-705
3 2
x4 x4
1
E131542
E131541
Installation
3. Torque: 10 Nm
1. NOTE: The profile of the special tool must be
in contact with the oil pump sprocket.
3
2
303-705 2 x2
x4
1
1
E131544
4. Refer to: Oil Pan (303-01 Engine - 3.2L

E131543
2011.50 Ranger
Engine Front Seal

303-1310 303-679A
Holding Wrench, Crankshaft Remover/Installer, Engine
Front Cover Inspection Plate
E87614 E62024
Removal
NOTE: Removal steps in this procedure may 1. Refer to: Cooling Fan Motor and Shroud (303-03
contain installation details. Engine Cooling - 3.2L Duratorq-TDCi
Installation).
2. 1.Do not completely loosen the crankshaft pulley
bolts.
x2
1 x3
2
x3
303-1310
E131305
3. CAUTION: Rotate the seal assembly

until it releases. Failure to follow this
2011.50 Ranger
instruction may result in damage to the instruction may result in damage to the
seal assembly. seal assembly.
Special Tool(s): 303-679A 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
303-679A installed.
Special Tool(s): 303-679A
E131306
Installation 303-679A
1. NOTE: Make sure that the mounting face is E131365
clean and lubricated.

3. Remove the alignment sleeve after the seal is
fully installed.
E131367
4. CAUTION: The crankshaft pulley bolts

E131312 must not be used more than 3 times.
Torque:
• Stage 1: 45 Nm
until it locks. Failure to follow this
• Stage 2: 120°
2011.50 Ranger
2 x3
1
x3
303-1310
E131366

Installation).
2011.50 Ranger
Crankshaft Rear Seal(21 468 4)

Special Tool(s)
Vehicles with automatic transmission
303-254
Locking Tool, Flywheel 1. Refer to: Transmission - 2WD (307-01
Automatic Transmission/Transaxle - Vehicles
With: 6-Speed Automatic Transaxle - 6R80,
Removal).
Refer to: Transmission - 4WD (307-01
21135
Materials Removal).
Name Specification Vehicles with manual transmission

Silicone Sealant LB WSE-M4G323-A4 / 2. Refer to: Clutch Disc and Pressure Plate
2U7J-M4G323-AA (308-01 Clutch - Vehicles With: 6-Speed
Manual Transmission - MT82, Removal and
Removal Installation).
NOTE: Removal steps in this procedure may All vehicles

x8
303-254
E131391
2011.50 Ranger
4. 2. NOTE: Install the new crankshaft rear seal
carrier within five minutes of applying the
recommended sealant.
Material: Silicone Sealant LB (WSE-M4G323-A4
x8
3mm
E131392
Installation
E131393
All vehicles
1. 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
E131398
1
8
5
E131394
2011.50 Ranger
4. NOTE: New crankshaft rear seal carriers are 6. Special Tool(s): 303-254
supplied with an alignment sleeve which must Torque:
be removed after installation. • Stage 1: 15 Nm
• Stage 2: 30 Nm
Torque: 10 Nm
• Stage 3: 75 Nm
• Stage 4: 45°
2
4
6
3 5
7
7
2
1
3 8
1 6 4
8
5
E131395 303-254
E131397
5. NOTE: Make sure that the flywheel is in full
contact with the crankshaft flange before
installing the flywheel bolts. Vehicles with manual transmission
Hand tighten the bolts at this stage. 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
x8 Automatic Transmission/Transaxle - Vehicles
Installation).
Refer to: Transmission - 4WD (307-01
Installation).
E131396
2011.50 Ranger
REMOVAL
Engine — Vehicles With: 6-Speed Manual Transmission -

MT82(21 132 0; 21 132 6; 21 132 7)
Removal 7.
Special Tool(s) / General Equipment
303-122
Lifting Bracket, Engine 1
x4
21068A
2
Transmission Jack

Operation).
E128859
3. Refer to: Cooling System Draining, Filling and 8.
Bleeding - 2.2L Duratorq-TDCi (88kW/120PS)
- Puma/2.2L Duratorq-TDCi (96kW/130PS) -
Puma (303-03 Engine Cooling - 3.2L
4. Refer to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging (412-00
Climate Control System - General Information,
E129579
9.
6.
x4 x9
E131903
E130132
2011.50 Ranger
REMOVAL
10. 12. Refer to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
13.
x7
x2
E131904
11. E134162
14. On both sides.
x4
E131940
E128788
15.
2011.50 Ranger
REMOVAL
x2
x6
x7
E133552
17.
16.
E135104
E135105
2011.50 Ranger
REMOVAL
18. Refer to: Battery (414-01 Battery, Mounting and 23.
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 x2
and Installation).
Refer to: Powertrain Control Module (PCM)
Duratorq-TDCi (88kW/120PS) - Puma/2.2L
21.
E130890
24.
2
x4
E139349
22.
E134703
x2
E139350
2011.50 Ranger
REMOVAL
25. 30. Refer to: Starter Motor - 3.2L Duratorq-TDCi
(148kW/200PS) - Puma (303-06 Starting
System - 2.2L Duratorq-TDCi (88kW/120PS)
31.
E132020
E131212
(88kW/120PS) - Puma/2.2L Duratorq-TDCi 32.
(96kW/130PS) - Puma/2.2L Duratorq-TDCi
Installation).
27. Refer to: Radiator (303-03 Engine Cooling - 3.2L
28. Refer to: Condenser - 2.2L Duratorq-TDCi
(148kW/200PS) - Puma (412-01 Climate
Control, Removal and Installation).
29.
E129816
E135125
2011.50 Ranger
REMOVAL
33. Refer to: Air Cleaner - 3.2L Duratorq-TDCi 36.
(148kW/200PS) - Puma (303-12 Intake Air
Distribution and Filtering - 2.2L Duratorq-TDCi
Installation).
34. NOTE: Make sure that all openings are sealed.
E134704
37.
E132021
35. CAUTION: Cap the power steering line

E132022
2
38.
1
x2
x2
3
E133693
E130529
2011.50 Ranger
REMOVAL
39. Refer to: Catalytic Converter (309-00 Exhaust 43.
40.
E134708
44.
E134705
41.
E134707
45. WARNING: Make sure that transmission

assembly is on wooden blocks and
secured with suitable retaining straps.
2 CAUTION: Do not tilt the transmission.
This may cause damage to the pilot
bearing.
E134706
42.
E132699
2011.50 Ranger
REMOVAL
Tie and support the transmission to the chassis 47.
with a suitable strap.
General Equipment: Transmission Jack
x2
x4
E132701
E128845 48. On both sides.
46.
E132028
x3
303-122
E132702
E68699
2011.50 Ranger
REMOVAL
50.
E132036
51.
x3 2
E132029
2011.50 Ranger
REMOVAL
Engine — Vehicles With: 6-Speed Automatic Transaxle -

6R80(21 132 0; 21 132 6; 21 132 7)
Removal 7.
303-122
Lifting Bracket, Engine 1
x4
21068A
2
Transmission Jack

Operation).
E128859
3. Refer to: Cooling System Draining, Filling and 8.
E129579
9.
6.
x4 x9
E131903
E130132
2011.50 Ranger
REMOVAL
10. 12. Refer to: Cowl Panel Grille (501-02 Front End
13.
x7
x2
E131904
11. E134162
14. On both sides.
x4
E131940
E128788
15.
2011.50 Ranger
REMOVAL
x2
x6
x7
E133552
17.
16.
E135104
E135105
2011.50 Ranger
REMOVAL
18. Refer to: Battery (414-01 Battery, Mounting and 23.
20. Refer to: Powertrain Control Module (PCM)
Duratorq-TDCi (88kW/120PS) - Puma/2.2L x2
21.
E130890
24.
x4
E139349
22.
E134703
x2
E139350
2011.50 Ranger
REMOVAL
25. 30. Refer to: Starter Motor - 3.2L Duratorq-TDCi
31.
E132020
E131212
(88kW/120PS) - Puma/2.2L Duratorq-TDCi 32. Refer to: Transmission Fluid Cooler (307-02
(96kW/130PS) - Puma/2.2L Duratorq-TDCi Transmission/Transaxle Cooling, Removal
(110kW/150PS) - Puma, Removal and and Installation).
Installation).
33.
29.
E129816
E135125
2011.50 Ranger
REMOVAL
34. Refer to: Air Cleaner - 3.2L Duratorq-TDCi 37.
Installation).
35. NOTE: Make sure that all openings are sealed.
E134704
38.
E132021
36. CAUTION: Cap the power steering line

E132022
2
39.
1
x2
x2
3
E133693
E130529
2011.50 Ranger
REMOVAL
41.
E134708
45.
E134705
42.
E134707
46. WARNING: Make sure that transmission

assembly is on wooden blocks and
secured with suitable retaining straps.
2 CAUTION: Do not tilt the transmission.
This may cause damage to the pilot
bearing.
E134706
43.
E132699
2011.50 Ranger
REMOVAL
Tie and support the transmission to the chassis 47.
with a suitable strap.
General Equipment: Transmission Jack
x2
x3
E135451
E128845 48.
x2
E135453
49.
2011.50 Ranger
REMOVAL
303-1310 60
x6
2
E135454
51. On both sides.

50.
x2
E132028
303-122
E135452
E68699
2011.50 Ranger
REMOVAL
53.
E132036
54.
x3 2
E132029
2011.50 Ranger
REMOVAL
Engine Accessories(21 139 4)

Removal Special Tool(s) / General Equipment
Special Tool(s) / General Equipment 303-435-06
303-122 Mounting Bracket for 303-435
Lifting Bracket, Engine
21031B
21068A
303-435-11B
303-1310 Mounting Plate for
Holding Wrench, Crankshaft 303-435-06
E68386
E87614
303-679
303-1317 Remover/Installer, Engine
Locking Tool, Fuel Injection Front Cover Inspection Plate
Pump Sprocket
303679
E75376
303-679A
Remover, Crankshaft Timing Front Cover Inspection Plate
Pulley
E62024
21132
1/2 Inch Square Drive Breaker Bar

303-254 Dowel with a Diameter of 6 mm
Locking Tool, Flywheel
1. Install the Special Tool(s): 303-122
303-122
21135
303-435
Mounting Stand
21187
E68699
2011.50 Ranger
REMOVAL
2. 5.
1 1
x2
2
2
3
E138792 E134641
3. 6.
x2
2
E138420 E138440
4. 7. Install the Special Tool(s): 303-435-11B
303-435-11B
E138421 E87393
2011.50 Ranger
REMOVAL
8. Install the Special Tool(s): 303-435-06, 303-435 9. Remove the Special Tool(s): 303-122
303-122
303-435-06
303-435
E87394
E68699
10. General Equipment: 1/2 Inch Square Drive

Breaker Bar
General Equipment: Dowel with a Diameter of
6 mm
E131376
2011.50 Ranger
REMOVAL
11. CAUTION: Take extra care not to 13.
damage the wiring harnesses.
2
1
3 E138429
14.
5 x2
x3
4 E138430
E131417
15.
12.
x5
E138787
x4
E138459
2011.50 Ranger
REMOVAL
16. 18.
x1
2
0
x3
E131141

damaged.
NOTE: The studs are to be reused unless
damaged. E138422
19.
E131142
E135272
20.
E135273
21.
2011.50 Ranger
REMOVAL
E138790
2011.50 Ranger
REMOVAL
22. 25. CAUTION: Make sure that all openings
are sealed. Use new blanking caps.
E138788
26.
E135428
23.
1
x3
x4
3
2
E130891
E138424
24.
27.
E130893
E138786
2011.50 Ranger
REMOVAL
28. 31. Special Tool(s): 303-254
303-254
x2
E138425
29.
E133584
x2
32. NOTE: Do not loosen the bolts more than 2
turns.
6 1
E138436
30. 4
x2 3
x3
2
5
E129960
E87416
2011.50 Ranger
REMOVAL
33. Special Tool(s): 303-254 36.
x5
x5
E129826
x8
37. CAUTIONS:
303-254 Make sure that the fuel line remains in
contact at both ends until both unions
E131391
nuts have been unscrewed and the area
around the joints thoroughly cleaned.
34. 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.
x8
Make sure that all openings are sealed.
Use new blanking caps.
x3
2
1
1
E131392
35.
E133633
1
x1
E130894
2011.50 Ranger
REMOVAL
38. 41.
2
x5
x5
1
x2
E129832 E138789
39. 42.
x4
E129828 E135430
40. 43.
E129584 E138434
2011.50 Ranger
REMOVAL
44. Special Tool(s): 303-679 47.
303-679
E129923
45.
E129689
48. Special Tool(s): 303-1317, 303-249
303-1317 303-249
E97216
E97222
303-1317
49.
E97221
x3
E129690
2011.50 Ranger
REMOVAL
50. 52.
x2 1
x6
E131304
51.
E138791
53.
x2
x8
E138793 E138785
54.
x3
E134532
2011.50 Ranger
REMOVAL
x2
1 x3
2
x3
303-1310
E131305
56. Special Tool(s): 303-679A
303-679A
E131306
2011.50 Ranger
DISASSEMBLY
Engine(21 134 8)
Disassembly
1. Torque: 23 Nm
100-010
Remover, O-Ring Seal
17063
303-1317
Locking Tool, Fuel Injection
Pump Sprocket
E75376
x3
E129690
303-249
Remover, Crankshaft Timing
Pulley 2. NOTE: Make sure that a new component is
installed.
Torque: 45 Nm
21132
303-428
Separator, Oil Pan
21179
303-679 E138701
Remover/Installer, Engine
Front Cover Inspection Plate
303679
2 mm Punch
2011.50 Ranger
DISASSEMBLY
3. Torque: 22 Nm 6. Remove the Special Tool(s): 303-679
303-679
E129923
7.
E129689
4. Remove the Special Tool(s): 303-1317, 303-249
303-1317 303-249 x20

x2
E75620
E97222
303-428
303-1317
E87411
E97221
2011.50 Ranger
DISASSEMBLY
9. 12.
x8
x4
E94201 E138963
10. Special Tool(s): 100-010 13. NOTE: The gasket is to be reused unless
General Equipment: 2 mm Punch damaged.
100-010
1
3
E87423
11. Remove and discard the timing chain tensioner.

General Equipment: 2 mm Punch
E131106
14.
x2
x3
x3
x2
E87424
x2
E95464
2011.50 Ranger
DISASSEMBLY
15. 18. WARNING: Be prepared to collect
escaping fluid.
x12
11 7 3 1 5 9
12 8 4 2 6 10
E94096
1
16.
x2
E130800
303-428
E94111
17.
8
x1
22 6 18 2 14 4 16 8 20
11 E138964
10
20.
9 12
21 5 17 1 13 3 15 7 19
E94113
E76144
2011.50 Ranger
DISASSEMBLY
21. 24. NOTE: Note the position of each component
before removal.
x6
0
x1
E138437
E94118
22.
25. NOTE: Note the position of each component
before removal.
E94117
23. E94157

before removal.
E95356
E94158
2011.50 Ranger
DISASSEMBLY
before removal.
2
x1
E94161

before removal.
E94173

before removal.
3
1
x5
x5
2
E138965
2011.50 Ranger
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
Installation).
2. Torque : 13Nm
x5
E138395
3. Torque : 23Nm
x2
E138008
Assembly
1. To assemble, reverse the disassembly
procedure.
2011.50 Ranger
ASSEMBLY
Engine(21 134 8)
Assembly Special Tool(s) / General Equipment
Special Tool(s) / General Equipment 303-428
205-044 Separator, Oil Pan
Holding Fixture, Dial Indicator
Gauge
21179
15008
303-432
205-069 Holding Fixture, Dial Indicator
Dial Indicator Gauge (Metric) Gauge (Cylinder Liner
Protrusion)
21183
15046
303-682
205-070 Aligner, Engine Front Cover
Holding Fixture, Dial Indicator
Gauge
303682
15022A
6 mm Drill Bit
303-1562 Piston Ring Compressor
Timing Tool
Round-Ended Steel Rule
Materials
E131853 Name Specification
Engine Oil - 5W-30 WSS-M2C913-C
303-254 Silicone Sealant LB WSE-M4G323-A4 /
Locking Tool, Flywheel 2U7J-M4G323-AA
21135
303-391
Setting Gauge, Crankshaft
21166
2011.50 Ranger
ASSEMBLY
1. NOTE: Make sure that these components are NOTE: Install all the bolts finger tight before
installed to the noted removal position. final tightening.
Material: Engine Oil - 5W-30 (WSS-M2C913-C) Torque:
engine oil • Stage 1: 15 Nm
Torque: 10 Nm • Stage 2: 20 Nm
• Stage 3: 35 Nm
• Stage 4: 80 Nm
3 • Stage 5: 90°
1
x5
2
x1
x5
2
E138965
2. NOTE: Make sure that these components are E94161

installed to the noted removal position.
Material: Engine Oil - 5W-30 (WSS-M2C913-C)
4. NOTE: Make sure that these components are
engine oil
General Equipment: Piston Ring Compressor
engine oil
x5
E94362
3. NOTE: Make sure that these components are

x5
E94363
2011.50 Ranger
ASSEMBLY
5. NOTE: Make sure that these components are 8. NOTE: Only tighten the bolts finger tight at this
installed to the noted removal position. stage.
engine oil
E94117
E94387
9. The ladder frame and the cylinder block must
be aligned so that the side clearance does not
6. NOTE: Make sure that these components are exceed 0.05 mm overlap to 0.05 mm gap.
installed to the noted removal position. Special Tool(s): 303-432
NOTE: Install all the bolts finger tight before
final tightening.
Torque:
• Stage 1: 25 Nm
• Stage 2: 60 Nm
• Stage 3: 90°
303-432
0
x1
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.
E94118
General Equipment: Round-Ended Steel Rule
7.
E76155
E95356
2011.50 Ranger
ASSEMBLY
11. Torque: 23 Nm 14. Take measurements at two different points on
the oil pump sprocket and align the oil pump
sprocket.
19 12 24
8 11 22 Special Tool(s): 205-044, 205-069
14
15 7 3 2 6 18
205-044
17
16 9
20 4 1 5 10 13 25
21
23
E94393 205-069
12. NOTE: Only tighten the bolts finger tight at this

stage. E87422
15. Torque: 10 Nm
x6
x6
E138437
E138437
13. Take a reference measurement from the front
face of the crankshaft sprocket.
16.
Special Tool(s): 205-044, 205-069
205-069
205-044
E87421 E76144
17. NOTE: A new crankshaft rear seal carrier is

be removed until the crankshaft rear seal is fully
2011.50 Ranger
ASSEMBLY
installed. Failure to follow this instruction may 19. NOTE: Install the new crankshaft rear seal
result in damage to the vehicle. carrier within five minutes of applying the
recommended sealant.
• Clean the area on the engine before installing
a new crankshaft rear seal carrier. Material: Silicone Sealant LB (WSE-M4G323-A4
• Check the two foam pads are located as / 2U7J-M4G323-AA) sealant
shown on the ladder frame gasket.
3mm
E58864
18. Material: Engine Oil - 5W-30 (WSS-M2C913-C)

engine oil
E131393
20. CAUTION: A new crankshaft rear seal

Initially hand tighten the fasteners.
2
4
E131398 7
1
8
5
E131394
2011.50 Ranger
ASSEMBLY
21. NOTE: New crankshaft rear seal carriers are 23. Special Tool(s): 303-254
supplied with an alignment sleeve which must Torque:
be removed after installation. • Stage 1: 15 Nm
• Stage 2: 30 Nm
Torque: 20 Nm
• Stage 3: 75 Nm
2
4
6 3 5
7
7
2
1
8
3
6 4
1
8
5 303-254
E131395
E131397
22. NOTE: Make sure that the flywheel is in full

24. Special Tool(s): 205-069, 205-070
contact with the crankshaft flange before
installing the flywheel bolts.
Initially hand tighten the fasteners. 205-070
205-069
x8
TIE0034799
25. NOTE: Do not fully tighten the crankshaft

position sensor bracket retaining bolts at this
stage.
E131396
x2
E87418
2011.50 Ranger
ASSEMBLY
26. NOTE: After installation do not move the special 30. NOTE: Rotate the crankshaft counterclockwise.
tool. 1. Rotate the crankshaft until the piston No. one
Special Tool(s): 303-391 achieves zero on the dial indicator gauge.
2. Mark the position on the flywheel primary
mass.
303-391 Special Tool(s): 303-391
303-391
TIE0034801
27. Rotate the crankshaft until piston No. one is

approximately 10 mm before top dead center TIE0034803
(TDC).
Special Tool(s): 205-069, 205-070 31. Repeat the previous steps to make sure that
the marking is correct.
205-070 32. NOTE: The middle of the markings is TDC.

Measure the distance between the two marks.
205-069
TIE0034799
28. Zero the dial indicator gauge.

29. Mark the position on the flywheel primary mass. TIE0034804
33. Divide the amount by two and mark the position
TDC on the flywheel primary mass.
303-391
TIE0034802
2011.50 Ranger
ASSEMBLY
34. Measure the circumference of the flywheel NOTE: Make sure that the special tool is fully
primary mass. located in the flywheel so that the engine cannot
be rotated in either direction.
303-1562
TIE0034809
35. Multiply the circumference by 0.1388 and mark E138698

the calculated amount on the flywheel primary
mass by measuring from TDC counterclockwise. 38. Remove the Special Tool(s): 303-1562
36. 1. First mark. Torque: 25 Nm
2. Second mark.
3. Determined TDC. 303-1562
4. Determined 50 degrees before top dead
center (BTDC).
1 3 2
4
x2
E138699
39. WARNING: Do not use metal scrapers,

wire brushes, power abrasive discs or
TIE0034805 other abrasive means to clean the
sealing surfaces. These tools cause
37. CAUTION: Do not turn the crankshaft scratches and gouges that make leak
when the special tool is fully located paths. Use a plastic scraping tool to
into the flywheel. Failure to follow this remove all traces of the head gasket.
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.
E131632
2011.50 Ranger
ASSEMBLY
40. NOTE: Measure the piston protrusion of each 43. NOTE: Make sure that a new component is
cylinder at top dead center (TDC). installed.
Measure the distance between the piston crown
and the cylinder block at the points indicated.
E94452
E131633
44.
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
E131636
45. CAUTION: Make sure that new cylinder

head bolts are installed.
205-069 Torque:
E131634
• Bolts 13 to 22: 10 Nm
42. Determine the cylinder head gasket. • Bolts 1 to 12: 180°
Refer to: Specifications (303-01 Engine - 3.2L • Bolts 1 to 12: 50 Nm
Duratorq-TDCi (148kW/200PS) - Puma, • Bolts 13 to 22: 180°
Specifications). • Bolts 13 to 22: 25 Nm
21 6 18 2 14
10 4
16 7
20
9
11
22
5 12
17 1 13 3 15 8 19
E131637
2011.50 Ranger
ASSEMBLY
46. Material: Silicone Sealant LB (WSE-M4G323-A4 49. Special Tool(s): 303-1562
303-1562
2,5mm
E138698
E95380
50. NOTE: Make sure that the installation marks

47. Torque: are aligned.
• Bolts 1 to 26 23 Nm General Equipment: 6 mm Drill Bit
• Bolts 27, 28 10 Nm Torque: 33 Nm
26 22 14 8 6 16 24
18 10 4 2 12 20
x3
x3
17 9 3 1 11 19
25 21 13 7 5 15 23
27
28
E94486
48. Torque:
• Stage 1: 10 Nm
• Stage 2: 30°
E95422

x12
11 7 3 1 5 9
12 8 4 2 6 10
E94096
2011.50 Ranger
ASSEMBLY
52. 1. Torque: 15 Nm 55. Rotate the engine two revolutions.
2. Torque: 40 Nm
3. CAUTION: Make sure that new bolts
are installed.
303-1562
x2 1
x2 1
2
E138698
57. Check the position of the timing marks and

correct if necessary.
x2 3 General Equipment: 6 mm Drill Bit
E95442

installed.
Torque: 15 Nm
x2
E95424
E75760
54. Remove the Special Tool(s): 303-1562 59. Remove the Special Tool(s): 303-1562
303-1562 303-1562
E138698 E138698
2011.50 Ranger
ASSEMBLY
installed.
3mm
E131106
61. Torque: 10 Nm
x8
E131310
x4
E138963
Torque:
• 1 10 Nm
62. NOTE: Make sure that a new component is • 2 14 Nm
installed.
303-682
1
2
x20
x2
E87427
E94201
63. NOTE: The component must be installed within

5 minutes of applying the sealant.
2011.50 Ranger
ASSEMBLY
65. NOTE: Do not damage the mating faces. 67. Torque:
• Stage 1: 12 Nm
• Stage 2: 15 Nm
11
4 12
1 13
9 5
7
303-428 10
14
2
16
6
18
17 8
15
E133924
E130957
66. CAUTION: Install the oil pan within five

68. NOTE: The seal is to be reused unless
minutes of applying the sealer.
damaged.
NOTE: Do not damage the mating faces.
Torque: 35 Nm
3mm
1
E130956
E130800
2011.50 Ranger
INSTALLATION
Engine — Vehicles With: 6-Speed Manual Transmission -

MT82(21 132 0; 21 132 6; 21 132 7)
Installation 4. NOTE: Hand tighten the nut at this stage.
Special Tool(s)
303-122
21068A

General Information, Description and E132028
Operation).
2. Special Tool(s): 303-122 5. NOTE: Hand tighten the nuts at this stage.
303-122
x3 2
E68699
E132029
3.
6. NOTE: Hand tighten the nut at this stage.
E135094
E135148
2011.50 Ranger
INSTALLATION
7. Initially hand tighten the fasteners. 10. 1. Torque: 48 Nm
Torque: 48 Nm 2. Torque: 25 Nm
x3 2
x2
1
E132029
x4
11. Torque: 80 Nm
E132701
8. Initially hand tighten the fasteners.

Torque: 48 Nm
E135094
12. 1. Remove the Special Tool(s): 303-122
303-122
x3
E132702
9. Torque: 80 Nm E68699
E132028
2011.50 Ranger
INSTALLATION
13. Torque: 13 Nm 16.
E134707 E134705
14. 17. Torque: 10 Nm
2
E134708
15. Torque: 12 Nm
E134706
E132699
2011.50 Ranger
INSTALLATION
19. Torque: 22 Nm
x2 E134704
22. Torque: 35 Nm
x2
E130529
3
20.
E133693
23.
E132022
E132021
2011.50 Ranger
INSTALLATION
24. Torque: 22 Nm 27. Refer to: Condenser - 2.2L Duratorq-TDCi
E135146
25. Refer to: Starter Motor - 3.2L Duratorq-TDCi (110kW/150PS) - Puma, Removal and
(148kW/200PS) - Puma (303-06 Starting Installation).
30. Refer to: Air Cleaner - 3.2L Duratorq-TDCi
26. (110kW/150PS) - Puma/3.2L Duratorq-TDCi
Installation).
31.
E135125
E129816
2011.50 Ranger
INSTALLATION
32. 35. Torque: 5 Nm
E135147 E135105
33. Torque: 10 Nm 36.
x2
E130890 E135104
34. Torque: 18 Nm
x2
E139350
2011.50 Ranger
INSTALLATION
37. 38. Refer to: Powertrain Control Module (PCM)
Duratec-HE (122kW/165PS) - MI4, Removal
and Installation).
Refer to: Powertrain Control Module (PCM)
x4 Duratorq-TDCi (148kW/200PS) - Puma,
40. Refer to: Battery (414-01 Battery, Mounting and
41. Torque: 10 Nm
E139349
x6 x2
x7
E133552
2011.50 Ranger
INSTALLATION
42. On both sides. 46.
x7
E135145
47.
E128788
x9
43. Torque: 10 Nm
x2
E131903

49. Torque: 30 Nm
E134162
44. Refer to: Cowl Panel Grille (501-02 Front End

45. Torque: 25 Nm
x4
x4
E131940 E135111
2011.50 Ranger
INSTALLATION
51. Refer to: Cooling System Draining, Filling and
2011.50 Ranger
INSTALLATION
Engine — Vehicles With: 6-Speed Automatic Transaxle -

6R80(21 132 0; 21 132 6; 21 132 7)
Installation 4. NOTE: Hand tighten the nut at this stage.
Special Tool(s)
303-122
21068A

General Information, Description and E132028
Operation).
2. Special Tool(s): 303-122 5. NOTE: Hand tighten the nuts at this stage.
303-122
x3 2
E68699
E132029
3.
6. NOTE: Hand tighten the nut at this stage.
E135094
E135148
2011.50 Ranger
INSTALLATION
7. Initially hand tighten the fasteners. 10. 1. Torque: 48 Nm
Torque: 48 Nm 2. Torque: 48 Nm
x3 2
x2
x3
E132029
11. Torque: 80 Nm
E135451

Torque: 48 Nm
E132028
12. 1. Remove the Special Tool(s): 303-122
x2 303-122
E135452
9. Torque: 80 Nm E68699
E135094
2011.50 Ranger
INSTALLATION
13. Torque: 13 Nm 14. Torque: 40 Nm
E134707
303-1310 60
x6
2
E135454
2011.50 Ranger
INSTALLATION
15. Torque: 22 Nm 18.
x2
E134705
19. Torque: 10 Nm
1
E135453
16.
E134708 E134706
17. Torque: 12 Nm
E132699
2011.50 Ranger
INSTALLATION
21. Torque: 22 Nm
x2 E134704
24. Torque: 35 Nm
x2
E130529
3
22.
E133693
25.
E132022
E132021
2011.50 Ranger
INSTALLATION
26. Torque: 22 Nm 29. Refer to: Transmission Fluid Cooler (307-02
Transmission/Transaxle Cooling, Removal
and Installation).
E135146
27. Refer to: Starter Motor - 3.2L Duratorq-TDCi
Installation).
Puma, Removal and Installation). 33. Refer to: Air Cleaner - 3.2L Duratorq-TDCi
28.
Installation).
34.
E135125
E129816
2011.50 Ranger
INSTALLATION
E135147 E135105
36. Torque: 10 Nm 39.
x2
E130890 E135104
37. Torque: 18 Nm
x2
E139350
2011.50 Ranger
INSTALLATION
40. 41. Refer to: Powertrain Control Module (PCM)
x4
43. Refer to: Battery (414-01 Battery, Mounting and
44. Torque: 10 Nm
E139349
x6 x2
x7
E133552
2011.50 Ranger
INSTALLATION
45. On both sides. 49.
x7
E135145
50.
E128788
x9
46. Torque: 10 Nm
x2
E131903

52. Torque: 30 Nm
E134162
47. Refer to: Cowl Panel Grille (501-02 Front End

48. Torque: 25 Nm
x4
x4
E131940 E135111
2011.50 Ranger
INSTALLATION
53. Torque: 20 Nm
x4
E130132

55. Refer to: Cooling System Draining, Filling and
2011.50 Ranger
INSTALLATION
Engine Accessories(21 139 4)

Installation Special Tool(s) / General Equipment
Special Tool(s) / General Equipment 303-435-06
303-122 Mounting Bracket for 303-435
21031B
21068A
303-435-11B
303-1310 Mounting Plate for
Holding Wrench, Crankshaft 303-435-06
E68386
E87614
303-679
Locking Tool, Fuel Injection Front Cover Inspection Plate
Pump Sprocket
303679
E75376
303-679A
Remover, Crankshaft Timing Front Cover Inspection Plate
Pulley
E62024
21132
308-204
303-254 Aligner, Clutch Disc
Locking Tool, Flywheel
16067
21135
1/2 Inch Square Drive Breaker Bar

303-435 Dowel with a Diameter of 6 mm
Mounting Stand
Materials
Name Specification
Silicone Sealant LB WSE-M4G323-A4 /
21187
2U7J-M4G323-AA
2011.50 Ranger
INSTALLATION
2
4
1
8
5
E131398 E131394
2. NOTE: Install the new crankshaft rear seal 4. NOTE: New crankshaft rear seal carriers are
carrier within five minutes of applying the supplied with an alignment sleeve which must
recommended sealant. be removed after installation.
Material: Silicone Sealant LB (WSE-M4G323-A4 Torque: 20 Nm
2
3mm
4
1
8
5
E131395
E131393
3. CAUTION: A new crankshaft rear seal

2011.50 Ranger
INSTALLATION
5. Special Tool(s): 303-254 7. Special Tool(s): 303-254
Torque:
• Stage 1: 15 Nm
• Stage 2: 30 Nm
• Stage 3: 75 Nm
3 5
303-254
7
2
1
8
E133584
6 4
6. NOTE: Make sure that the flywheel is in full 303-254

contact with the crankshaft flange before E131397
installing the flywheel bolts.
Initially hand tighten the fasteners.
8. NOTE: The cone on the special tool must only
be tightened finger tight to prevent damage to
the clutch disc.
x8
E131396
308-204
E129961
2011.50 Ranger
INSTALLATION
9. NOTE: Only tighten the bolt finger tight at this 11. Remove the Special Tool(s): 308-204
stage.
308-204
1
308-204
E129984
E129962 12. NOTE: Make sure that a new component is

installed.
10. CAUTION: Tighten the clutch pressure Torque: 7 Nm
plate retaining bolts by two turns at a
time in the sequence shown.
Torque: 45 Nm
x3
6 1
4 308-204 3 E87416
2
5
E129963
2011.50 Ranger
INSTALLATION
x3
E129690 E129689
14. NOTE: Make sure that a new component is 16. Remove the Special Tool(s): 303-1317, 303-249
installed.
Torque: 45 Nm
303-1317 303-249
E97222
E138701 17. Remove the Special Tool(s): 303-1317
303-1317
E97221
2011.50 Ranger
INSTALLATION
18. Remove the Special Tool(s): 303-679 21. Torque: 23 Nm
303-679
E129923
x2
19. Torque: 12 Nm
E138793
2. Torque: 23 Nm
x8
2
E138785
20. Torque: 23 Nm
x2 1
E131304
23. Torque: 48 Nm
x6
x3
E138791
E134532
2011.50 Ranger
INSTALLATION
24. NOTE: Make sure that the mounting face is be removed until the crankshaft rear seal is fully
clean and lubricated. installed.
Special Tool(s): 303-679A
303-679A
E131365
26. Remove the alignment sleeve after the seal is

fully installed.
E131312

until it locks. Failure to follow this
instruction may result in damage to the
seal assembly.
NOTE: A new crankshaft front seal carrier is
E131367
27. CAUTION: Crankshaft pulley retaining

bolts must only be used three times.
NOTE: Initially hand tighten the fasteners.
Torque:
• Stage 1: 45 Nm
• Stage 2: 120°
2011.50 Ranger
INSTALLATION
2 x3
1
x3
303-1310
E131366
30. Torque: 15 Nm
28. Torque: 9 Nm
1
x1
E130894
E138434
31. Record the new fuel injector correction factor

29. code.
2
x5
x5
1 F100-0000
E138789 E129647
32. NOTE: Using a socket (or similar), press the

new fuel injector copper seals onto the fuel
2011.50 Ranger
INSTALLATION
injectors making sure that the copper seals are nuts have been unscrewed and the area
pushed fully home to prevent uneven clamping. 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
E129584 Duratorq-TDCi (88kW/120PS) - Puma/2.2L
33. CAUTION: Make sure that new bolts are General Procedures).
installed. Torque: 12 Nm
Torque:
• Stage 1: 5 Nm
• Stage 2: 180°
x3
2
1
1
x4
E129828
34. Torque:
E133633
• Stage 1: 7 Nm
• Stage 2: 20 Nm
36. Torque:
• Stage 1: 20 Nm
• Stage 2: 25 Nm
x5
x2
E129832
x5
35. CAUTIONS:
E129826
Make sure that the fuel line remains in
contact at both ends until both unions
2011.50 Ranger
INSTALLATION
x2
x3
E138436
38. Torque: 12 Nm
E138424
41. CAUTION: Make sure that all openings

are sealed. Use new blanking caps.
x2
E138425
39.
E138788
42.
E138786
E130893
2011.50 Ranger
INSTALLATION
43. 3. Torque: 25 Nm 45.
x4
3
2
E130891 E135272
44. 46.
E135273
2011.50 Ranger
INSTALLATION
E138790
2011.50 Ranger
INSTALLATION
x5
E138787
51. Torque: 20 Nm
E138422 x2

damaged.
NOTE: The studs are to be reused unless
damaged.
E138430
52. Torque: 25 Nm
E131142
2. Torque: 23 Nm
E138429
1
x1
2
0
x3
E131141
2011.50 Ranger
INSTALLATION
53. Torque: 25 Nm 54. CAUTION: Take extra care not to
damage the wiring harnesses.
4. Torque: 15 Nm
5. Torque: 48 Nm
2
1
3
x4
E138459
5
x3
4
E131417
55. General Equipment: 1/2 Inch Square Drive

Breaker Bar
General Equipment: Dowel with a Diameter of
6 mm
2011.50 Ranger
INSTALLATION
E131377
57. Remove the Special Tool(s): 303-435-06,

56. Install the Special Tool(s): 303-122 303-435
303-122
303-435-06
303-435
E68699 E87394
2011.50 Ranger
INSTALLATION
58. Remove the Special Tool(s): 303-435-11B 61.
303-435-11B
E87393 E138421
x2
2
E138440 E138420
60. Torque: 23 Nm 63. 1. Torque: 35 Nm

2. Torque: 32 Nm
1
1
x2
2
2
E134641 3
E138792
2011.50 Ranger

3.2 Diesel. Distribución. Puesta A Punto.

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3.2 Diesel. Distribución. Puesta A Punto.

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Available Formats

303-01C-1 Engine — 3.

2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C-1

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

DESCRIPTION AND OPERATION

REMOVAL AND INSTALLATION

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Engine Oil Capacity

Cylinder Block Dimensions

Connecting Rod Dimensions

Piston Pin Dimensions

Cylinder Head Dimensions

Oil Pressure Specifications

Lubricants, Fluids, Sealers and Adhesives

Engine type identification

Item Description Item Description

The interval indicator must be reset after an oil

Oil level/temperature sensor

An oil level/temperature sensor located on the front

Engine – Component Location

Item Description Item Description

Intake Manifold(21 183 0)

7. Refer to: Exhaust Gas Recirculation (EGR) 10.

Exhaust Manifold(21 187 0)

Make sure that new bolts are installed.

11. CAUTION: Make sure that new studs are

Valve Cover(21 141 0)

WARNING: Do not smoke or carry lighted

2. NOTE: Make sure that the rocker arms do not

4. NOTE: Make sure that the installation marks

7. NOTE: Make sure that a new component is

5. Remove the 6 mm drill bit. E75760

8. Remove the Special Tool(s): 303-1562

9. Rotate the engine two revolutions.

11. Check the valve timing by inserting the drill bits.

12. Remove the 6 mm drill bits.

3. Refer to: Valve Cover (303-01 Engine - 3.2L

Valve Stem Seals(21 238 0)

Timing Cover(21 146 0)

7. Refer to: Lifting (100-02 Jacking and Lifting,

3. To install, reverse the removal procedure.

Cylinder Head(21 163 0)

NOTE: Removal steps in this procedure may

2. NOTE: Measure the piston protrusion of each 5.

6. CAUTION: Make sure that new cylinder

4. NOTE: Note the thickness of the gasket. 22

Oil Pan(21 154 0)

3. Refer to: Lifting (100-02 Jacking and Lifting,

8. CAUTION: Take extra care when

9. WARNING: Be prepared to collect

4. To install, reverse the removal procedure.

Oil Pump(21 714 0)

4. Refer to: Oil Pan (303-01 Engine - 3.2L

Engine Front Seal

3. CAUTION: Rotate the seal assembly

clean and lubricated.

4. CAUTION: The crankshaft pulley bolts

5. Refer to: Cooling Fan Motor and Shroud (303-03

Crankshaft Rear Seal(21 468 4)

Name Specification Vehicles with manual transmission

NOTE: Removal steps in this procedure may All vehicles

Vehicles with automatic transmission

Engine — Vehicles With: 6-Speed Manual Transmission -

1. Refer to: Health and Safety Precautions (100-00