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303-01B Engine - 2.2L Duratorq-TDCi (63kW/85PS) – Puma/2.2L Duratorq-TDCi (103kW/140PS) 2006 - 2015

(PG)/2.2L Duratorq-TDCi (81kW/110PS) – Puma/2.2L Duratorq-TDCi (85kW/115PS) – Puma/2.2L Transit
Duratorq-TDCi (96kW/130PS) – Puma
Procedure
Installation revision date:
12/22/2010

Engine - Long Wheelbase

Special Tool(s) /
General Equipment

205-775

Protector, Halfshaft Seal

211-188

Expander, Teflon Seal

303-122

Lifting Bracket, Engine

Floor Crane
Hose Clamp Remover/Installer
Mounting Table Set

1. Torque: 30 lb.ft (40 Nm)

 
 
 
 
 
 

2. Torque: 30 lb.ft (40 Nm)

 
 
 
 
 
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3.  
WARNING: Make sure that the engine and transmission assembly is on wooden blocks and
secured with suitable retaining straps.

Use the General Equipment: Mounting Table Set

 
 
 
 
 
 

4. Remove the special tool.

Use Special Service Tool: 303-122

 Lifting Bracket, Engine.
Use the General Equipment: Floor Crane

 
 
 
 
 
 

5. Check the thread and surrounding area for rust.

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6.

 
 
 
 
 
 

7.

 
 
 
 
 
 

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8. NOTICE: Make sure that new bolts are installed.

NOTICE: Make sure that new nuts are installed.

NOTE: Only tighten the nuts and bolts finger tight at this stage.

 
 
 
 
 
 

9. NOTICE: Make sure that new bolts are installed.

NOTICE: Make sure that new nuts are installed.

NOTE: Only tighten the nut and bolts finger tight at this stage.

 
 
 
 
 
 

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10. Raise and support the vehicle.

Refer to: Jacking (100-02 Jacking and Lifting, Description and Operation).

Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

11. Install a new snap ring.

Use Special Service Tool: 205-775

 Protector, Halfshaft Seal.

 
 
 
 
 
 

12. Use Special Service Tool: 205-775

 Protector, Halfshaft Seal.

 
 
 
 
 
 

13. Torque: 18 lb.ft (25 Nm)

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14. 1. Torque: 76 lb.ft (103 Nm)

2. Torque: 17 lb.ft (23 Nm)

 
 
 
 
 
 

15. Torque: 85 lb.ft (115 Nm)

 
 
 
 
 
 

16.  
WARNING: Make sure that a new nut is installed.

NOTICE: Make sure that the ball joint ball does not rotate.

Lower arm ball joint retaining nut flat diameter 24 mm.

Torque: 111 lb.ft (150 Nm)

Lower arm ball joint retaining nut flat diameter 30 mm.

Torque: 184 lb.ft (250 Nm)

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17. NOTICE: Make sure that the ball joint ball does not rotate.

Torque: 41 lb.ft (55 Nm)

 
 
 
 
 
 

18. NOTICE: Make sure that the ball joint ball does not rotate.

Torque: 59 lb.ft (80 Nm)

 
 
 
 
 
 

19. NOTE: Only tighten the bolts finger tight at this stage.

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20. Lower the vehicle.

21. 1. Torque: 85 lb.ft (115 Nm)

2. Torque: 52 lb.ft (70 Nm)

 
 
 
 
 
 

22. 1. Torque: 98 lb.ft (133 Nm)

2. Torque: 52 lb.ft (70 Nm)

 
 
 
 
 
 

23. Torque: 35 lb.ft (48 Nm)

 
 
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24.

 
 
 
 
 
 

25.

 
 
 
 
 
 

26. NOTICE: If the fluid is spilled on the paintwork, the affected area must be immediately washed down
with cold water.

 
 
 
 
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27.

 
 
 
 
 
 

28. Use Special Service Tool: 211-188

 Expander, Teflon Seal.

 
 
 
 
 
 

29. 1. Torque: 18 lb.ft (24 Nm)

2. Torque: 17 lb.ft (23 Nm)

 
 
 
 
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30. Use the General Equipment: Hose Clamp Remover/Installer

 
 
 
 
 
 

31.

 
 
 
 
 
 

32. Use the General Equipment: Hose Clamp Remover/Installer

 
 
 
 

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33. Use the General Equipment: Hose Clamp Remover/Installer

 
 
 
 
 
 

34. Refer to: Jacking (100-02 Jacking and Lifting, Description and Operation).

Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

35. Torque:

  1:
 
18 lb.ft (25 Nm)

  2:
 
18 lb.ft (25 Nm)

 
 
 
 
 
 

36. NOTE: Make sure that the exhaust flanges are correctly aligned.

 
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37.

 
 
 
 
 
 

38. Adjust the gearshift cables.

Refer to: Gearshift Cable Adjustment - 5-Speed Manual Transmission – VXT75 (308-00 Manual Transmission
and Clutch - General Information, General Procedures).

39. Install the following items:

1. Condenser core.

Refer to: Condenser Core (412-03A Air Conditioning (A/C), Removal and Installation).

2. Radiator.

Refer to: Radiator (303-03 Engine Cooling, Removal and Installation).

3. Compressor to condenser discharge line.

Refer to: Compressor to Condenser Discharge Line - 2.2L Duratorq-TDCi (Puma) Diesel (412-03A Air
Conditioning (A/C), Removal and Installation).

4. Suction acuumulator to compressor line.

Refer to: Suction Accumulator to Compressor Line - 2.2L Duratorq-TDCi (Puma) Diesel (412-03A Air
Conditioning (A/C), Removal and Installation).

5. Front wheels and tires.

Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).

6. Front bumper.

Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).

7. Air cleaner.

Refer to: Air Cleaner - 2.2L Duratorq-TDCi (Puma) Diesel (303-12B Intake Air Distribution and Filtering -
2.2L Duratorq-TDCi (63kW/85PS) – Puma/2.2L Duratorq-TDCi (103kW/140PS) (PG)/2.2L Duratorq-TDCi
(81kW/110PS) – Puma/2.2L Duratorq-TDCi (85kW/115PS) – Puma/2.2L Duratorq-TDCi (96kW/130PS) –
Puma, Removal and Installation).

40. Fill and bleed the cooling system.

Refer to: Engine Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (Puma) Diesel/2.4L
Duratorq-TDCi (Puma) Diesel/3.2L Duratorq-TDCi (Puma) Diesel, Vehicles With: Fuel Fired Booster Heater
(303-03 Engine Cooling, General Procedures).

Refer to: Engine Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (Puma) Diesel/2.4L

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Duratorq-TDCi (Puma) Diesel/3.2L Duratorq-TDCi (Puma) Diesel, Vehicles Without: Fuel Fired Booster Heater
(303-03 Engine Cooling, General Procedures).

41. Bleed the fuel system.

© Copyright 2022, Ford Motor Company.

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