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 generator.
   For additional information, refer to: Generator - 2.4L Duratorq-TDCi (Puma) Diesel/3.2L Duratorq-TDCi (Puma) Diesel (414-02 Generator and Regulator, Removal and Installation).
   

3. Remove the intake manifold.
   For additional information, refer to: Intake Manifold (303-01C Engine - 2.4L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
   

4. Remove the exhaust manifold.
   For additional information, refer to: Exhaust Manifold (303-01C Engine - 2.4L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
   

5. Remove the exhaust gas recirculation (EGR) cooler.
   For additional information, refer to: Exhaust Gas Recirculation (EGR) Cooler - 3.2L Duratorq-TDCi (Puma) Diesel (303-08 Engine Emission Control, Removal and Installation).
   

6. Remove the camshafts.
   For additional information, refer to: Camshafts (303-01C Engine - 2.4L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
   

7. Using the special tool, disconnect the coolant expansion tank hose and the radiator upper hose.

8. Detach the power steering pump from the engine and position it to one side (four bolts).

9. Detach the generator wiring harness from the engine lifting eye and the power steering pump and generator mounting bracket.

10. Remove the power steering pump and generator mounting bracket.

11. 

    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 the cylinder block with Loctite 7070.

2. Check the cylinder head for distortion.
   For additional information, refer to: Specifications (303-01D Engine - 3.2L Duratorq-TDCi (Puma) Diesel, Specifications).
   

3. 

   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.

4. 

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

5. Determine the cylinder head gasket.
   For additional information, refer to: Specifications (303-01D Engine - 3.2L Duratorq-TDCi (Puma) Diesel, Specifications).
   

6. 

   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.

7. Install the power steering pump and generator mounting bracket.

8. Attach the power steering pump to the engine (four bolts).

9. Using the special tool, connect the coolant expansion tank hose and the radiator upper hose.

10. Install the camshafts.
    For additional information, refer to: Camshafts (303-01C Engine - 2.4L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
    

11. Install the EGR cooler.
    For additional information, refer to: Exhaust Gas Recirculation (EGR) Cooler - 3.2L Duratorq-TDCi (Puma) Diesel (303-08 Engine Emission Control, Removal and Installation).
    

12. Install the exhaust manifold.
    For additional information, refer to: Exhaust Manifold (303-01C Engine - 2.4L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
    

13. Install the intake manifold.
    For additional information, refer to: Intake Manifold (303-01C Engine - 2.4L Duratorq-TDCi (Puma) Diesel, In-vehicle Repair).
    

14. Install the generator.
    For additional information, refer to: Generator - 2.4L Duratorq-TDCi (Puma) Diesel/3.2L Duratorq-TDCi (Puma) Diesel (414-02 Generator and Regulator, Removal and Installation).
    

15. 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).