Section 14 (Engine - 3.2L DURATORQ-TDCI (148KW/200PS) - Puma): Disassembly: Engine
WARNING: This page is about a different variant/trim than selected.
For information on Ford Color Coded Illustrations refer to OEM Color Coding .
Special Tool(s) / General Equipment
| 100-010 Remover, O-Ring Seal |
|
|---|---|
| 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® Metal Surface Prep Wipes ZC-31-B |
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NOTE:
During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.
NOTE:
Assembly of the engine requires various inspections/measurements of the engine components. These inspections/measurements will aid in determining if the engine components will require replacement. Refer to Engine System - General Information
.
NOTE:
During the removal or installation of components, cap, tape or otherwise appropriately protect all openings and tubes/fittings to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation.
NOTE:
Refer to Engine Component View .
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- Install Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.
- Remove the bolts and the flexplate.
- Discard the bolts.
- Install the engine on a mounting stand. Use the General Equipment: Mounting Stand
- Remove the floor crane. Use the General Equipment: Floor Crane
- Remove the bolts and the LH engine mount bracket.
- Remove the bolts and the RH engine mount bracket.
- Disconnect the coolant hose.
- Remove the bolt and disconnect the retainers. Remove the coolant hose.
- Remove the lower radiator hose. Use the General Equipment: Hose Clamp Remover/Installer
- Disconnect and remove the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer
- Disconnect and remove the coolant hose.
- Disconnect and remove the coolant hose.
- Disconnect and remove the coolant hose.
- Remove the bolts. Disconnect and remove the coolant tube.
- Remove the bolt and the heat shield.
- Disconnect the CKP sensor electrical connector.
- Disconnect the wire harness retainers and the electrical connectors.
- Disconnect the wire harness retainers and electrical connectors. Disconnect the hose from the crankcase vent hose.
- Remove the cover and the nut. Disconnect the electrical connector and wire retainer.
- Remove the bolts. Disconnect the electrical connectors and the wire retainer.
- Disconnect the electrical connector and the wire retainers. If equipped, disconnect the block heater.
- Disconnect the oil pressure switch electrical connector and wire retainer.
- Disconnect the TP sensor electrical connector and wire retainer.
- Disconnect the electrical connectors and wire retainer.
- 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.
- Remove the engine wire harness and if equipped, the block heater cord.
- Remove the bolt and mounting bracket. Remove the stud.
- Remove the nuts, bolt and the accessory drive belt tensioner.
- Remove the studs.
- Remove the bolts and the generator.
- Remove the bolts, bracket and the lifting eye.
- Disconnect the vacuum hose and the retaining clip.
- Disconnect the vacuum hose at the vacuum pump.
- Remove the bolts and the bracket assembly.
- Remove the bolt and the CKP sensor.
- Remove the bolts and the CKP sensor bracket.
- Remove the turbocharger heat shield bolt.
- Remove the bolts and the turbocharger heat shield.
- Remove and discard the turbocharger oil supply tube assembly.
- Remove the bolt for the turbocharger drain tube.
- Remove the bolts and the turbocharger drain tube.
- Inspect the O-ring, replace if necessary. Remove and discard the gasket.
- Remove and discard the nuts.
- Remove the nut and the turbocharger. Discard the nut.
- Remove the bolt and the oil level indicator tube assembly.
- Remove the bolts and the heat shield.
- Remove and discard the EGR cooler clamp.
- Remove the bolt for the EGR cooler. Discard the EGR valve gasket.
- Remove the bolt and the EGR cooler.
- Remove and discard the EGR cooler gasket.
- Remove the bolts and the vacuum pump.
- Remove and discard the vacuum pump seal.
- Remove the nuts and the EGR valve.
- Remove the bolts and the mixer tube.
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NOTE: The O-ring seal is to be reused unless damaged.
Inspect the O-ring. Remove and discard the gasket.
- Remove the bolts and the coolant pump.
- Remove the bolt and the fuel return tube bracket.
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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. Discard the return tube assembly. Refer to: Quick Release Coupling .
- Remove the bolts and the intake manifold.
- Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be reused.
- Remove the glow plug harness.
- Remove the glow plugs.
- Remove the oil pressure switch.
- Remove the bolts, stud bolts and the oil cooler.
- Remove and discard the gasket.
- Remove the bolts and the accessory drive belt idler assembly. Remove the idler pulley assembly.
- Remove the nut, bolts and the coolant connector.
- Inspect the O-ring.
- Using the special tool, loosen the crankshaft pulley bolts. Use Special Service Tool: 303-1310 Holding Wrench, Crankshaft.
- Remove and discard the bolts. Remove the crankshaft pulley.
- Remove the crankshaft pulley washer.
- 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.
- Remove and discard the crankshaft front seal.
- Remove the nuts and bolts. Remove and discard the engine front cover.
- Remove and discard the engine front cover gasket.
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation
.
- Align the timing marks on the timing chain.
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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.
- Remove Special Service Tool: 303-1587 Timing Tool, Crankshaft.
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- Using the special tool, release the timing chain tensioner. Use Special Service Tool: 100-010 Remover, O-Ring Seal.
- Push the plunger into the timing chain tensioner.
- Using the General Equipment: 2 mm Punch, install the 2 mm punch into the timing chain tensioner. Use the General Equipment: 2 mm Punch
- Remove the bolts and the timing chain tensioner. Discard the tensioner.
- Remove the bolts and the timing chain guides.
- Remove the bolts, the camshaft sprockets and the timing chain.
- Remove and discard the fuel injector supply tubes.
- Remove the bolts and the fuel rail supply tube. Discard the fuel rail supply tube.
- Remove the bolts, bracket and the fuel rail.
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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.
- Remove and discard the fuel injector sealing washers.
- Remove the nut, bolts and the fuel injection pump bracket.
- Remove the bolts and the fuel injection pump bracket. Discard the fuel injection pump bolt.
- Remove the bolts and fuel injection pump bracket. Discard the fuel injection pump bolt.
- Remove the nut and the fuel injection pump bracket.
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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.
- 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.
- Remove the stud bolts and the fuel injection pump.
- Remove and discard the fuel injection pump O-ring seal.
- Remove the bolts and the coolant manifold. Discard the gasket.
- If equipped, remove the block heater.
- Remove the bolt and the CMP sensor.
- Remove the NVH padding.
- Loosen the bolts and remove the valve cover.
- Remove and discard the valve cover gasket.
- Remove and discard the valve cover seals.
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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
- Remove the nut, bolt and the thermostat bracket.
- Remove the bolts and the valve rocker arm housing.
- Remove the bolts and the upper cylinder head.
- Remove the camshafts.
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation
.
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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.
- Remove and discard the cylinder head gasket and the dowels.
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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
- Check the cylinder head distortion. Refer to: Cylinder Head Distortion .
- Check the cylinder block distortion. Refer to: Cylinder Block Distortion .
- Remove the oil level sensor.
- Remove the nuts and bolts. Remove and discard the oil pan.
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation
.
- Remove the bolts and the oil pickup tube.
- Inspect the O-ring.
- Remove the banjo bolt and the oil feedback pipe.
- Inspect the O-ring.
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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.
- Remove the bolt and the oil pump drive tensioner.
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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.
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NOTE: Do not remove the Oil Pump Aligner until the engine is reassembled.
Remove the oil pump chain.
- Remove the oil pump guide stud.
- Remove the bolts and the crankshaft rear seal. Discard the crankshaft rear seal.
- Remove the bolts and the ladderframe. Remove and discard the ladderframe gaskets.
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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
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- Inspect ridge.
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NOTE: Remove the carbon buildup, do not scratch the cylinder wall. Remove all debris from the cylinder.
Clean with abrasive pad.
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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.
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NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Remove the pistons.
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NOTE: If the connecting rod bearings are being reused, mark them in order for correct orientation and reassembly.
Remove the connecting rod bearings.
- Inspect the pistons. Refer to: Piston Inspection .
- If necessary, remove the crankshaft sprocket.
- If necessary, remove the crankshaft sprocket washer.
- Remove and discard the bolts. Remove the crankshaft bearing caps.
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NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
Remove the crankshaft lower bearings.
- Remove the crankshaft.
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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.
- Remove and discard the bolts. Remove the piston cooling nozzles.
- Remove and discard the cylinder block oil filter.
- Inspect the cylinder bore taper. Refer to: Cylinder Bore Taper .