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

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
Oil Drain Equipment
Vehicle/Axle Stands
Hose Clamp Remover/Installer

• 1.
  
  With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting - Overview .

• 2.
  
  Disconnect the battery ground cable. Refer to: Battery Disconnect and Connect - Vehicles With: Dual Batteries .

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

• 4.
  
  
  • Remove the oil drain plug and drain the engine oil.

    Use the General Equipment: Oil Drain Equipment

  • Install the drain plug.

    Torque: 29 lb.ft (39 Nm)

Courtesy of FORD MOTOR COMPANY

• 5.
  
  Remove and discard the oil filter.

  Use the General Equipment: Oil Drain Equipment

Courtesy of FORD MOTOR COMPANY

• 6.
  
  Loosen the clamp and remove the turbocharger CAC pipe.

Courtesy of FORD MOTOR COMPANY

• 7.
  
  Disconnect and position aside the hose from the ACL (air cleaner) housing.

Courtesy of FORD MOTOR COMPANY

• 8.
  
  Remove the fuel vaporizer system glow plug. Refer to: Fuel Vaporizer System Glow Plug .

• 9.
  
  Remove and discard the catalytic converter nuts.

Courtesy of FORD MOTOR COMPANY

• 10.
  
  Position the hose aside, remove the oil filler cap and remove the engine appearance cover.

Courtesy of FORD MOTOR COMPANY

• 11.
  
  Disconnect and position aside the electrical connector.

Courtesy of FORD MOTOR COMPANY

• 12.
  
  Disconnect the ECT sensor electrical connector and hose retainer. Remove the nut and position aside the engine wire harness.

Courtesy of FORD MOTOR COMPANY

• 13.
  
  Disconnect the coolant hoses from the thermostat assembly.

  Use the General Equipment: Hose Clamp Remover/Installer

Courtesy of FORD MOTOR COMPANY

• 14.
  
  Disconnect the coolant hose. Remove the bolt and the thermostat assembly.

  Use the General Equipment: Hose Clamp Remover/Installer

Courtesy of FORD MOTOR COMPANY

• 15.
  
  Disconnect the fuel tubes. Refer to: Quick Release Coupling .

Courtesy of FORD MOTOR COMPANY

• 16.
  
  Remove the degas bottle. Refer to: Degas Bottle .

• 17.
  
  Disconnect the electrical connectors.

Courtesy of FORD MOTOR COMPANY

• 18.
  
  Disconnect and remove the coolant hoses. Remove the cable cover.

Courtesy of FORD MOTOR COMPANY

• 19.
  
  Remove the nut and disconnect the wire retainer, position aside the cable.

Courtesy of FORD MOTOR COMPANY

• 20.
  
  Disconnect the wire harness retainer from the BJB bracket.

Courtesy of FORD MOTOR COMPANY

• 21.
  
  Disconnect the electrical connector. Remove the bolt and position aside the BJB.

Courtesy of FORD MOTOR COMPANY

• 22.
  
  Remove the bolts for the A/C tubes.

Courtesy of FORD MOTOR COMPANY

• 23.
  
  Disconnect the wire harness retainer and remove the bolt.

Courtesy of FORD MOTOR COMPANY

• 24.
  
  Disconnect the wire harness retainers. Remove the bolts and the BJB bracket.

Courtesy of FORD MOTOR COMPANY

• 25.
  
  Disconnect the retainer and position aside the engine wire harness.

Courtesy of FORD MOTOR COMPANY

• 26.
  
  Disconnect the coolant connector.

  Use the General Equipment: Hose Clamp Remover/Installer

Courtesy of FORD MOTOR COMPANY

• 27.
  
  Disconnect the heater hose at the intake.

  Use the General Equipment: Hose Clamp Remover/Installer

Courtesy of FORD MOTOR COMPANY

• 28.
  
  Disconnect the brake booster hose.

Courtesy of FORD MOTOR COMPANY

• 29.
  
  Disconnect the tube retainers and position aside the transmission vent tube.

Courtesy of FORD MOTOR COMPANY

• 30.
  
  
  NOTE: The catalytic converter bolts are 2 different sizes. Note the position for installation.

  Remove the bolts and the catalytic converter bracket.

Courtesy of FORD MOTOR COMPANY

• 31.
  
  Remove the bolts, exhaust shield and the gasket. Discard the gasket and bolts.

Courtesy of FORD MOTOR COMPANY

• 32.
  
  Position aside the catalytic converter. Remove and discard the turbocharger gasket.

Courtesy of FORD MOTOR COMPANY

• 33.
  
  Remove the bolt and position the bracket aside.

Courtesy of FORD MOTOR COMPANY

• 34.
  
  Remove nuts and bolts, position aside the power steering pump.

Courtesy of FORD MOTOR COMPANY

• 35.
  
  Remove the bolt and disconnect the transmission cooler tubes.

Courtesy of FORD MOTOR COMPANY

• 36.
  
  Remove the nut and position aside transmission cooler tube bracket.

Courtesy of FORD MOTOR COMPANY

• 37.
  
  Remove the bolts and the transmission cooler tubes.

Courtesy of FORD MOTOR COMPANY

• 38.
  
  Disconnect the CAC temperature sensor electrical connector and the wire retainer.

Courtesy of FORD MOTOR COMPANY

• 39.
  
  Loosen the clamp and remove the CAC pipe.

Courtesy of FORD MOTOR COMPANY

• 40.
  
  
  NOTE: Make sure that all openings are sealed.

  Remove the nut and disconnect the A/C tube.

Courtesy of FORD MOTOR COMPANY

• 41.
  
  
  NOTE: Make sure that all openings are sealed.

  If equipped with rear A/C, remove the nut and disconnect the A/C tube.

Courtesy of FORD MOTOR COMPANY

• 42.
  
  Disconnect the A/C electrical connector and wire retainer.

Courtesy of FORD MOTOR COMPANY

• 43.
  
  Remove the bolts and the A/C compressor.

Courtesy of FORD MOTOR COMPANY

• 44.
  
  Remove the starter. Refer to: Starter Motor .

• 45.
  
  Disconnect the transmission wire retainers.

Courtesy of FORD MOTOR COMPANY

• 46.
  
  
  NOTE: Body removed for clarity.

  Disconnect the electrical connectors and wire retainers.

Courtesy of FORD MOTOR COMPANY

• 47.
  
  If equipped with rear heat, disconnect the coolant hoses.

Courtesy of FORD MOTOR COMPANY

• 48.
  
  Remove bolts and the torque converter cover.

Courtesy of FORD MOTOR COMPANY

• 49.
  
  
  NOTE: Index-mark the end of one torque converter stud and the flexplate for installation.
  NOTE: Using a strap wrench, rotate the engine clockwise.

  Remove and discard the torque converter nuts.

  Use the General Equipment: Strap Wrench

Courtesy of FORD MOTOR COMPANY

• 50.
  
  Position a stand under the transmission crossmember.

  Use the General Equipment: Vehicle/Axle Stands

Courtesy of FORD MOTOR COMPANY

• 51.
  
  
  • Remove the bolts and the front subframe braces for the transmission crossmember.
  • Lower the transmission crossmember 25 mm (1 inch).

Courtesy of FORD MOTOR COMPANY

• 52.
  
  Remove the upper engine-to-transmission bolts.

Courtesy of FORD MOTOR COMPANY

• 53.
  
  
  • Raise the transmission crossmember.
  • Install the front subframe braces and bolts for the transmission crossmember.

Courtesy of FORD MOTOR COMPANY

• 54.
  
  Remove the stand from the transmission crossmember.

Courtesy of FORD MOTOR COMPANY

• 55.
  
  
  NOTE: Engine removed for clarity.

  Support the transmission.

  • Position a 2x4 wooden board on the front subframe.
  • Secure the wooden board in place with a ratchet strap.
  • Position an additional wooden board between the transmission and the wooden board.

Courtesy of FORD MOTOR COMPANY

• 56.
  
  Remove the RH upper engine-to-transmission bolts.

Courtesy of FORD MOTOR COMPANY

• 57.
  
  Remove the RH lower engine-to-transmission bolt.

Courtesy of FORD MOTOR COMPANY

• 58.
  
  Remove the LH engine-to-transmission bolts.

Courtesy of FORD MOTOR COMPANY

• 59.
  
  
  • Position the powertrain lift table under the engine crossmember and install an adjustable mounting arm to the LH side of the cross member.

    Use the General Equipment: Adjustable Mounting Arm

  • Install an adjustable mounting arm to the left front corner of the engine.

    Use the General Equipment: Adjustable Mounting Arm

Courtesy of FORD MOTOR COMPANY

• 60.
  
  Install an adjustable mounting arm to the RH side of the cross member.

  Use the General Equipment: Adjustable Mounting Arm

Courtesy of FORD MOTOR COMPANY

• 61.
  
  Remove and discard the engine crossmember bolts from both sides.

Courtesy of FORD MOTOR COMPANY

• 62.
  
  Remove and discard the engine mount bolts from both sides.

Courtesy of FORD MOTOR COMPANY

• 63.
  
  Remove the engine crossmember brackets from both sides.

Courtesy of FORD MOTOR COMPANY

• 64.
  
  Remove and discard the engine crossmember bolts.

Courtesy of FORD MOTOR COMPANY

• 65.
  
  Separate the engine and crossmember assembly from the transmission.

Courtesy of FORD MOTOR COMPANY

• 66.
  
  Slide the engine forward and install the special tool.

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

Courtesy of FORD MOTOR COMPANY

• 67.
  
  Using the powertrain lift table, lower the engine from the vehicle.

Courtesy of FORD MOTOR COMPANY

• 68.
  
  Install the floor crane.

  Use the General Equipment: Floor Crane

Courtesy of FORD MOTOR COMPANY

• 69.
  
  Remove the nut from the adjustable mounting arm.

Courtesy of FORD MOTOR COMPANY

• 70.
  
  
  • Remove and discard the engine mount nuts.
  • Using the floor crane, lift the engine from the engine crossmember.

Courtesy of FORD MOTOR COMPANY

• 71.
  
  
  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)