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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:
12/4/2012

Engine - Medium Wheelbase/Short Wheelbase

Special Tool(s) /
General Equipment

204-605

Separator, Lower Arm Ball Joint

204-609

Protection Cap, Ball Joint Gaiter

205-775

Protector, Halfshaft Seal

211-188

Expander, Teflon Seal

303-122

Lifting Bracket, Engine

Floor Crane
Cable Ties
Hose Clamp Remover/Installer
Mounting Table Set
Retaining Strap
Wooden Block

Materials

Name Specification
Grease OK-LL
WSS-M1C273-A

GU7J-M1C73-AA  

1. Use Special Service Tool: 303-122

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

 
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2. Apply a thin coating.

Material: Grease OK-LL
/ GU7J-M1C73-AA
(WSS-M1C273-A)

 
 
 
 
 
 

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

 
 
 
 
 
 

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

 
 
 

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5. Torque: 26 lb.ft (35 Nm)

 
 
 
 
 
 

6.  
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

Use the General Equipment: Wooden Block

Use the General Equipment: Retaining Strap

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7. Remove Special Service Tool: 303-122

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

 
 
 
 
 
 

8. NOTICE: Make sure that no components catch.

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

9. 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.

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

NOTICE: Make sure that a new nut is installed.

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

 
 
 
 
 
 

11. Remove the General Equipment: Retaining Strap

Remove the General Equipment: Wooden Block

Remove the General Equipment: Mounting Table Set

 
 
 
 
 
 

12.

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13. NOTE: Use a new seal.

Use Special Service Tool: 211-188

 Expander, Teflon Seal.

 
 
 
 
 
 

14. Torque:

  1:
 
18 lb.ft (24 Nm)

  2:
 
17 lb.ft (23 Nm)

 
 
 
 
 
 

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15. Remove the special tool before completely installing the halfshaft.
Use Special Service Tool: 205-775
 Protector, Halfshaft Seal.

 
 
 
 
 
 

16. NOTE: Make sure that new components are installed.

Torque:

  Stage 1: 
53 lb.in (6 Nm)

  Stage 2: 
18 lb.ft (25 Nm)

 
 
 
 
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17.

 
 
 
 
 
 

18. Remove the special tool before completely installing the halfshaft.
Use Special Service Tool: 205-775
 Protector, Halfshaft Seal.

 
 
 
 
 
 

19.

 
 
 

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20. Torque:

  1:
 
76 lb.ft (103 Nm)

  2:
 
17 lb.ft (23 Nm)

 
 
 
 
 
 

21. NOTE: Make sure that new bolts are installed.

Torque: 85 lb.ft (115 Nm)

 
 
 
 
 
 

22. On both sides.

Use Special Service Tool: 204-605
 Separator, Lower Arm Ball Joint.

 
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23. On both sides.

Remove Special Service Tool: 204-609
 Protection Cap, Ball Joint Gaiter.

 
 
 
 
 
 

24.  
WARNING: Make sure that a new nut is installed.

On both sides.
Torque:

  Lower arm ball joint retaining nut flat diameter 24 mm:

 
111 lb.ft (150 Nm)

  Lower arm ball joint retaining nut flat diameter 30 mm:

 
184 lb.ft (250 Nm)

 
 
 
 
 
 

25.  
WARNING: Make sure that a new nut is installed.

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On both sides.
Torque: 59 lb.ft (80 Nm)

 
 
 
 
 
 

26.  
WARNING: Make sure that a new nut is installed.

On both sides.
Torque: 41 lb.ft (55 Nm)

 
 
 
 
 
 

Vehicles with air conditioning

27. Remove the General Equipment: Cable Ties

Torque: 18 lb.ft (25 Nm)

 
 
 
 
 
 

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28. Torque: 71 lb.in (8 Nm)

 
 
 
 
 
 

29.

 
 
 
 
 
 

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30. Torque: 22 lb.ft (30 Nm)

 
 
 
 
 
 

31.

 
 
 
 
 
 

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All vehicles

32. Torque:

  1:
 
85 lb.ft (115 Nm)

  2:
 
52 lb.ft (70 Nm)

 
 
 
 
 
 

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33. Torque:

  1:
 
98 lb.ft (133 Nm)

  2:
 
52 lb.ft (70 Nm)

 
 
 
 
 
 

34.  
WARNING: Be prepared to collect escaping fluid.

 
 
 
 
 

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35.

 
 
 
 
 
 

36.  
WARNING: Be prepared to collect escaping fluid.

Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General Information, Description and
Operation).

Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).

 
 
 
 
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37.

 
 
 
 
 
 

38. Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).

 
 
 
 
 
 

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39. Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).

Use the General Equipment: Hose Clamp Remover/Installer

 
 
 
 
 
 

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

 
 
 
 
 
 

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41. Torque: 53 lb.in (6 Nm)

 
 
 
 
 
 

42.

 
 
 
 
 
 

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43.

 
 
 
 
 
 

44. Refer to: Catalytic Converter - 2.2L Duratorq-TDCi (Puma) Diesel (309-00 Exhaust System)
.

Refer to: Diesel Particulate Filter (DPF) - 2.2L Duratorq-TDCi (Puma) Diesel (309-00D Exhaust System - 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).

45.

 
 
 
 
 
 

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46. Torque: 115 lb.in (13 Nm)

 
 
 
 
 
 

47.

 
 
 
 
 
 

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48. Torque: 89 lb.in (10 Nm)

 
 
 
 
 
 

49. 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).

50. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

51. Refer to: Power Steering System Filling (211-00 Steering System - General Information, General Procedures).

52. 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
Duratorq-TDCi (Puma) Diesel/3.2L Duratorq-TDCi (Puma) Diesel, Vehicles Without: Fuel Fired Booster Heater
(303-03 Engine Cooling, General Procedures).

53. Refer to: Fuel System Bleeding (310-00A Fuel System - General Information, General Procedures).

54. Refer to: Clutch System Bleeding - 5-Speed Manual Transmission – VXT75 (308-00 Manual Transmission and
Clutch - General Information, General Procedures).

Refer to: Clutch System Bleeding - 6-Speed Manual Transmission – VMT6 (308-00 Manual Transmission and
Clutch - General Information, General Procedures).

55. Check the transmission oil level.

© Copyright 2022, Ford Motor Company.

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