Ford Workshop Service and Repair Manuals

Dial Indicator Gauge (Metric)

205-069 (15-046)

Holding Fixture, Dial Indicator Gauge

205-070 (15-022A)

Remover/Installer, Cooling Hose Clamp

303-397 (24-003)

Holding Fixture, Dial Indicator Gauge

303-432 (21-183)

1. Drain the cooling system. For additional information, refer to: (303-03 Engine Cooling)

   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 (General Procedures),

   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 (General Procedures).

2. Remove the intake manifold.
   For additional information, refer to: Intake Manifold (303-01B Engine - 2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
   

3. Remove the exhaust manifold.
   For additional information, refer to: Exhaust Manifold (303-01B Engine - 2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
   

4. Remove the accessory drive belt tensioner bracket.

5. Disconnect the cylinder head temperature (CHT) sensor electrical connector.

6. Disconnect the degas hose from the thermostat housing.

7. Remove the valve cover.
   For additional information, refer to: Valve Cover (303-01B Engine - 2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
   

8. Remove the camshafts.
   For additional information, refer to: Camshafts (303-01B Engine - 2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
   

9. 

   CAUTION:Remove the cylinder head bolts in the sequence shown.
   Remove the cylinder head.
   • Discard the gasket and the bolts.

1. Clean the mating faces of the cylinder head and cylinder block.

2. 

   NOTE:Measure the piston protrusion of each cylinder at top dead center (TDC).
   Measure the distance between the piston crown and the cylinder block at the points indicated.

3. 

   NOTE:The largest measurement determines the choice of the cylinder head gasket.
   Using the special tools, measure the piston protrusion.

4. Determine the cylinder head gasket.
   For additional information, refer to: Specifications (303-01B Engine - 2.2L Duratorq-TDCi (Puma) Diesel, Specifications).
   

5. 

   CAUTION:Install new cylinder head bolts.
   Install the cylinder head.
   • Tighten the bolts in the sequence shown in eight stages.
   • Stage 1: Tighten bolts 1 through 10 to 10 Nm.
   • Stage 2: Tighten bolts 11 through 18 to 5 Nm.
   • Stage 3: Tighten bolts 1 through 10 to 20 Nm
   • Stage 4: Tighten bolts 11 through 18 to 10 Nm.
   • Stage 5: Tighten bolts 1 through 10 to 40 Nm.
   • Stage 6: Tighten bolts 11 through 18 to 20 Nm.
   • Stage 7: Tighten bolts 1 through 10 to 180 degrees.
   • Stage 8: Tighten bolts 11 through 18 to 180 degrees.

6. Install the camshafts.
   For additional information, refer to: Camshafts (303-01B Engine - 2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
   

7. Install the valve cover.
   For additional information, refer to: Valve Cover (303-01B Engine - 2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
   

8. Connect the degas hose to the thermostat housing.

9. Connect the CHT sensor electrical connector.

10. Install the accessory drive belt tensioner bracket.

11. Install the exhaust manifold.
    For additional information, refer to: Exhaust Manifold (303-01B Engine - 2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
    

12. Install the intake manifold.
    For additional information, refer to: Intake Manifold (303-01B Engine - 2.2L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
    

13. Fill and bleed the cooling system. For additional information, refer to: (303-03 Engine Cooling)

    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 (General Procedures),

    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 (General Procedures).