Section 16 (Engine - 3.2L DURATORQ-TDCI (148KW/200PS) - Puma): Disassembly: Engine
Special Tool(s) / General Equipment
| 205-036 (T70P-4067-A) Wrench | |
|---|---|
| 303-103 (T74P-6375-A) Holding Tool, Flywheel T74P-77000-A TKIT-2009TC-F |
|
| 303-1310 Holding Wrench, Crankshaft | |
| 303-1317 Locking Tool, Fuel Injection Pump Sprocket | |
| 303-1587 Timing Tool, Crankshaft | |
| 303-249 Remover, Crankshaft Timing Pulley | |
| 303-249-01 Adapter for 303-249 | |
| 303-679A Remover/Installer, Engine Front Cover Inspection Plate | |
| 303-705 Aligner, Oil Pump | |
| Floor Crane | |
| Mounting Stand | |
| Plastic Scraper | |
| Hose Clamp Remover/Installer | |
| 2 mm Punch | |
Materials
| Name | Specification |
|---|---|
| Motorcraft® Silicone Gasket Remover ZC-30-A | - |
| Motorcraft® Metal Surface Prep Wipes ZC-31-B | - |
| Motorcraft® Metal Brake Parts Cleaner PM-4-A, PM-4-B | - |
- 1.
- Install Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.
- Remove the bolts and the flexplate.
- Discard the bolts.
- 17.
Disconnect the wire harness retainers and electrical connectors. Disconnect the hose from the crankcase vent hose.
- 20.
Disconnect the electrical connector and the wire retainers. If equipped, disconnect the block heater.
- 24.
Disconnect the wire retainer and remove the nut for the ground wire. Disconnect the fuel injector electrical connectors and release the harness from the valve cover.
- 54.NOTE: The O-ring seal is to be reused unless damaged.
Inspect the O-ring. Remove and discard the gasket.
- 57.NOTE: Make sure that the fuel injector return line fitting retaining clips are removed prior to disconnecting the fuel injector fuel return lines from the fuel injectors or damage to the fuel injector return line fittings may occur.NOTE: The release slide is a disassembly aid only to help disconnect the fuel injector return line fitting from the fuel injector.NOTE: Be prepared to collect escaping fluid.
Remove and discard the fuel injector fuel return line fitting retaining clips from the fuel injectors.
- Push on the release slide while pulling up on the fuel injector return line fittings to disconnect the fuel injector fuel return lines from the fuel injectors. Remove the fuel pump supply tube and return tube assemblies. Refer to: Quick Release Coupling .
- 60.
Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be reused.
- 69.
Using the special tool, loosen the crankshaft pulley bolts.Use Special Service Tool: 303-1310 Holding Wrench, Crankshaft.
- 72.
Using the special tool, release the crankshaft front seal from the engine front cover.Use Special Service Tool: 303-679A Remover/Installer, Engine Front Cover Inspection Plate.
- 76.NOTE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces of the engine block. These tools cause scratches and gouges, which make leak paths. They also cause contamination that causes premature engine failure. Remove all traces of the gasket.
Make sure that the mating surface is clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation .
Use the General Equipment: Plastic Scraper
Material: Motorcraft® Silicone Gasket Remover / ZC-30-A
Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
- 77.NOTE: When the tool is properly installed, the locating pin will be at approximately at the 10 o'clock position.
Using the special tool, set the crankshaft position. Install Special Service Tool: 303-1587 Timing Tool, Crankshaft.
- 79.
- 1.
Using the special tool, release the timing chain tensioner.
- 2.
Push the plunger into the timing chain tensioner.
- 3.
Using the General Equipment: 2 mm Punch, install the 2 mm punch into the timing chain tensioner.Use the General Equipment: 2 mm Punch
- 1.
- 82.
Mark the timing chain links that align with the timing marks on the LH and the RH camshaft sprockets as shown in illustration.- Remove the bolts, camshaft sprockets and the timing chain.
- 86.NOTE: Do not use the actuator hollow screw and electrical connector housing for removal or damage to the fuel injectors will occur.NOTE: The PCM is programmed with an IQA code for each fuel injector. Note the fuel injector cylinder location for installation.
Remove the fuel injector clamp bolts. Remove the fuel injector clamps and the fuel injectors.
- 92.NOTE: This bolt has left hand threads.
Using the special tool, remove the bolt for the fuel injection pump sprocket.
Use Special Service Tool: 205-036 (T70P-4067-A) Wrench.
- 93.
Using the special tools, remove the fuel pump sprocket.Use Special Service Tool: 303-249 Remover, Crankshaft Timing Pulley, 303-249-01 Adapter for 303-249, 303-1317 Locking Tool, Fuel Injection Pump Sprocket.
- 103.NOTE: 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, which make leak paths.
Clean the valve cover.
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
- 108.NOTE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. They also cause contamination that causes premature engine failure. Remove all traces of the gasket.
Make sure that the mating surface is clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation .
Use the General Equipment: Plastic Scraper
Material: Motorcraft® Silicone Gasket Remover / ZC-30-A
Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
- 109.NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
Remove and discard the bolts. Remove the cylinder head.
- 111.NOTE: 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.NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the metal surface prep.NOTE: Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
Clean the cylinder head sealing surfaces.
Use the General Equipment: Plastic Scraper
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
- 112.
Check the cylinder head distortion. Refer to: Cylinder Head Distortion .
- 113.
Check the cylinder block distortion. Refer to: Cylinder Block Distortion .
- 116.NOTE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces of the engine block. These tools cause scratches and gouges, which make leak paths. They also cause contamination that causes premature engine failure. Remove all traces of the gasket.
Make sure that the mating surface is clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation .
Use the General Equipment: Plastic Scraper
Material: Motorcraft® Silicone Gasket Remover / ZC-30-A
Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
- 121.NOTE: Install the Oil Pump Aligner when the ladderframe is not removed or when reusing the original short block with the ladder frame installed.
Install the special tool to the engine block and finger tighten the nut and bolt. Push the special tool against the oil pump sprocket. Tighten the nut and bolt.
Install Special Service Tool: 303-705 Aligner, Oil Pump.
- 123.NOTE: Install the Oil Pump Aligner when the ladderframe is not removed or when reusing the original short block with the ladder frame installed.NOTE: Do not remove the Oil Pump Aligner until the engine is reassembled.
Remove the bolts. Position aside the oil pump chain and remove the oil pump.
- 124.NOTE: Do not remove the Oil Pump Aligner until the engine is reassembled.
Remove the oil pump chain.
- 128.NOTE: 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, which make leak paths.NOTE: Make sure the mating surface is clean and free of foreign material.
Clean the ladderframe sealing surfaces.
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
- 129.
- 1.
Inspect ridge.
- 2.NOTE: Remove the carbon buildup, do not scratch the cylinder wall. Remove all debris from the cylinder.
Clean with abrasive pad.
- 1.
- 130.NOTE: Clearly mark the connecting rods, connecting rod caps and the connecting rod bearings in numerical order for correct orientation reassembly.
Remove the bolts and the connecting rod caps. Discard the bolts.
- 131.NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Remove the pistons.
- 132.NOTE: If the connecting rod bearings are being reused, mark them in order for correct orientation and reassembly.
Remove the connecting rod bearings.
- 133.
Inspect the pistons. Refer to: Piston Inspection .
- 137.NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
Remove the crankshaft lower bearings.
- 139.NOTE: If the main bearing are being reused, mark them in order for correct orientation and reassembly.NOTE: The number four main has the thrust washer.
Remove the crankshaft upper bearings.
- 142.
Inspect the cylinder bore taper. Refer to: Cylinder Bore Taper .