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

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5. Remove and discard the oil filter. Use the General Equipment: Oil Drain Equipment

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

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

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8. Remove the fuel vaporizer system glow plug. Refer to: Fuel Vaporizer System Glow Plug .
9. Remove and discard the catalytic converter nuts.

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

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11. Disconnect and position aside the electrical connector.

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

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13. Disconnect the coolant hoses from the thermostat assembly. Use the General Equipment: Hose Clamp Remover/Installer

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14. Disconnect the coolant hose. Remove the bolt and the thermostat assembly. Use the General Equipment: Hose Clamp Remover/Installer

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

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16. Remove the degas bottle. Refer to: Degas Bottle .
17. Disconnect the electrical connectors.

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

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

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

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

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

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

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

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

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

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

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28. Disconnect the brake booster hose.

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

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

    Remove the bolts and the catalytic converter bracket.

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

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

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33. Remove the bolt and position the bracket aside.

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

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

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

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37. Remove the bolts and the transmission cooler tubes.

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

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39. Loosen the clamp and remove the CAC pipe.

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

    Remove the nut and disconnect the A/C tube.

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

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

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

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

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44. Remove the starter. Refer to: Starter Motor .
45. Disconnect the transmission wire retainers.

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46. NOTE: Body removed for clarity.

    Disconnect the electrical connectors and wire retainers.

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

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48. Remove bolts and the torque converter cover.

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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

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

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

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

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

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54. Remove the stand from the transmission crossmember.

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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.

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

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

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

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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

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60. Install an adjustable mounting arm to the RH side of the cross member. Use the General Equipment: Adjustable Mounting Arm

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

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

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63. Remove the engine crossmember brackets from both sides.

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64. Remove and discard the engine crossmember bolts.

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

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66. Slide the engine forward and install the special tool. Install Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.

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

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68. Install the floor crane. Use the General Equipment: Floor Crane

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69. Remove the nut from the adjustable mounting arm.

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

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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)