Section 14 (Engine - 3.2L DURATORQ-TDCI (148KW/200PS) - Puma): Installation: Engine

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Special Tool(s) / General Equipment 

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

Materials 

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)

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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.

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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, 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 (WSS-M2C938-A) (MERCON® LV,)

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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)

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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.