Section 16 (Engine - 3.2L DURATORQ-TDCI (148KW/200PS) - Puma): Installation: Engine

WARNING: This page is about a different variant/trim than selected.

Special Tool(s) / General Equipment

Courtesy of FORD MOTOR COMPANY	307-346 (T97T-7902-A) Retainer, Torque Converter TKIT-1997-F/FLM/LT TKIT-1998-LM (NavigatoR)
Strap Wrench
Floor Crane
Adjustable Mounting Arm
Vehicle/Axle Stands
Hose Clamp Remover/Installer

Materials

Name	Specification
Motorcraft® Multi-Purpose Grease Spray XL-5-A	ESB-M1C93-B
Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil XO-5W40-5Q3SD	WSS-M2C171-F1
Motorcraft® MERCON® LV Automatic Transmission Fluid XT-10-QLVC	MERCON® LVWSS-M2C938-A

1.

NOTE: Failure to inspect the components for debris may result in repeat failures.

NOTE: It may be necessary to use a borescope to inspect the components.

When an engine or turbocharger is replaced due to a failure, inspect the following components for potential metal debris. If evidence of debris is found, clean or replace the components as needed.
- CAC and the CAC tubes
- Intake air system
- Exhaust manifolds
- EGR cooler and pipes
- Diesel Oxidation Catalyst (DOC)
- Turbocharger (on engine failure only)

2.

Lubricate the torque converter pilot hub with multi-purpose grease.
Material: Motorcraft® Multi-Purpose Grease Spray / XL-5-A (ESB-M1C93-B)

GFD144648

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3.

Verify that the component alignment dowels are installed in the engine block.

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4.
- Align the flexplate-to-converter marks made during the removal.
- Align the torque converter stud and flexplate hole near the paint marks to the 12 o'clock position.

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5.
- Using the floor crane, lower the engine onto the engine crossmember.
  Use the General Equipment: Floor Crane
- Install the new engine mount nuts.
  Torque: 85 lb.ft (115 Nm)

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6.

Install the nut for the adjustable mounting arm.

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7.

Remove the floor crane.
Use the General Equipment: Floor Crane

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8.

Using the powertrain lift table, raise the engine into the vehicle.

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9.

Remove Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.

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10.

NOTE: Make sure the torque converter studs are aligned with the holes in the flexplate.

Align the engine to the transmission. Draw the engine to the transmission using the bolts.

Torque: 35 lb.ft (48 Nm)

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11.

Install the new engine crossmember bolts.
Torque: 46 lb.ft (63 Nm)

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12.

Position the engine crossmember brackets for both sides.

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13.

NOTE: Do not tighten the bolts at this time.

Install the new engine mount bolts for both sides.

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14.

Install the new frame bolts for both sides.
Torque: 46 lb.ft (63 Nm)

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15.

Tighten the bolts for the engine mount for both sides.
Torque: 22 lb.ft (30 Nm)

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16.

Remove the adjustable mounting arm from the RH side of the engine crossmember.
Use the General Equipment: Adjustable Mounting Arm

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17.
- Remove the adjustable mounting arm from the left front corner of the engine.
  Use the General Equipment: Adjustable Mounting Arm
- Remove the adjustable mounting arm from the LH side of the engine crossmember. Remove the powertrain lift table.
  Use the General Equipment: Adjustable Mounting Arm

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18.

Install the LH side engine-to-transmission bolt.
Torque: 35 lb.ft (48 Nm)

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19.

Install the RH upper engine-to-transmission bolts.
Torque: 35 lb.ft (48 Nm)

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20.

NOTE: Engine removed for clarity.

Remove the wooden boards and the ratchet strap.

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21.

Position a stand under the transmission crossmember.
Use the General Equipment: Vehicle/Axle Stands

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22.
- Remove the bolts and the front subframe braces for the transmission crossmember. Discard the bolts.
- Lower the transmission crossmember 25 mm (1 inch).

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23.

Install the upper engine-to-transmission bolts.
Torque: 35 lb.ft (48 Nm)

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24.
- Raise the transmission crossmember.
- Install the front subframe braces and new bolts for the transmission crossmember.
  Torque: 148 lb.ft (200 Nm)

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25.

Remove the stand from the transmission crossmember.

GFD144419

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26.

NOTE: Using a strap wrench, rotate the engine clockwise.

Install the new torque converter nuts.

Use the General Equipment: Strap Wrench

Torque: 35 lb.ft (48 Nm)

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27.

Install the torque converter cover.
Torque: 35 lb.ft (48 Nm)

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28.

If equipped with rear heat, connect the coolant hoses.

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29.

NOTE: Body removed for clarity.

Connect the transmission electrical connectors and wire retainers.

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30.

Connect the transmission wire retainers.

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31.

Install the starter. Refer to: Starter Motor .

32.

Install the A/C compressor and the bolts.
Torque: 18 lb.ft (25 Nm)

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33.

Connect the A/C electrical connector and retainer.

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34.

If equipped with rear A/C, connect the A/C tube and install the nut.
Torque: 133 lb.in (15 Nm)

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35.

Connect the A/C tube and install the nut.
Torque: 133 lb.in (15 Nm)

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36.

Install the CAC pipe and tighten the clamp.
Torque: 44 lb.in (5 Nm)

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37.

Connect the CAC temperature sensor electrical connector and the wire retainer.

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38.

NOTE: Transmission side shown in illustration, transmission cooler side similar.

NOTE: Lubricate with clean transmission oil.

Inspect the transmission cooler tube seals and backing rings, replace if necessary.

Material: Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (MERCON® LV) (WSS-M2C938-A)

GFD143819

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39.

Install the transmission cooler tubes and bolts.
Torque: 97 lb.in (11 Nm)

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40.

Position the transmission cooler tube bracket and install the nut.
Torque: 97 lb.in (11 Nm)

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41.

Install the transmission cooler tube bolt at the transmission.
Torque: 18 lb.ft (25 Nm)

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42.

Position the power steering pump and install the nuts and bolt.
Torque: 22 lb.ft (30 Nm)

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43.

Position back the bracket and install the bolt.
Torque: 106 lb.in (12 Nm)

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44.

Using a new turbocharger gasket, position back the catalytic converter.

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45.

Using a new gasket, install the exhaust heat shield and bolts.
Torque: 30 lb.ft (40 Nm)

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46.

NOTE: The catalytic converter bracket bolts are 2 different sizes. Install the bolts in the same location as they were removed.

Install the catalytic converter bracket and the bolts.

Torque: 18 lb.ft (25 Nm)

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47.

Position back the transmission vent tube and connect the retainers.

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48.

Connect the brake booster hose.

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49.

Connect the heater hose at the intake.
Use the General Equipment: Hose Clamp Remover/Installer

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50.

Connect the coolant connector.
Use the General Equipment: Hose Clamp Remover/Installer

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51.

Position the engine wire harness and connect the retainer.

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52.

Install the BJB bracket and the bolts. Connect the wire harness retainers.
Torque: 89 lb.in (10 Nm)

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53.

Install the bolt and connect the wire harness retainer.
Torque: 89 lb.in (10 Nm)

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54.

Install the bolts for the A/C tubes.
Torque: 97 lb.in (11 Nm)

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55.

Position back the BJB and install the bolt. Connect the electrical connector.
Torque: 53 lb.in (6 Nm)

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56.

Connect the wire retainer to the BJB bracket.

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57.

Position back the cable and connect the wire retainer. Install the nut.
Torque: 106 lb.in (12 Nm)

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58.

Install the cable cover. Install the coolant hoses.

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59.

Connect the electrical connectors.

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60.

Install the degas bottle. Refer to: Degas Bottle .

61.

Connect the fuel tubes. Refer to: Quick Release Coupling .

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62.

Install the thermostat assembly and the bolt. Connect the coolant hose.
Use the General Equipment: Hose Clamp Remover/Installer

Torque: 17 lb.ft (23 Nm)

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63.

Connect the coolant hoses to the thermostat assembly.
Use the General Equipment: Hose Clamp Remover/Installer

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64.

Position back the engine wire harness and install the nut. Connect the ECT sensor electrical connector.
Torque: 89 lb.in (10 Nm)

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65.

Connect the electrical connector and wire retainer.

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66.

Remove the oil filler cap and install the engine appearance cover. Install the oil filler cap and position back the coolant hose.

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67.

Install the catalytic converter nuts.
Torque: 30 lb.ft (40 Nm)

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68.

Install the fuel vaporizer system glow plug. Refer to: Fuel Vaporizer System Glow Plug .

69.

Position back and connect the hose to the air cleaner.

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70.

Install the CAC pipe.
Torque: 48 lb.in (5.4 Nm)

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71.

Install the oil filter.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)

GFD144344

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72.

Fill the engine with clean engine oil.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)

73.

Install the following items:
1. Install the air cleaner outlet tube. Refer to: Air Cleaner Outlet Pipe .
2. Install the cooling module. Refer to: Cooling Module .
3. Install the accessory drive belt. Refer to: Accessory Drive Belt .

74.

Connect the battery ground cable. Refer to: Battery Disconnect and Connect - Vehicles With: Dual Batteries .

75.

Bleed the fuel system. Refer to: Fuel System Bleeding .

76.

Check the transmission fluid level. Refer to: Transmission Fluid Level Check .

77.

Start the engine and check the exhaust for leaks.