Thursday, March 15, 2012

The detailed Engine Replacing Procedure For Ford?

This is Engine removal and installation procedure.

Its For AWD vehicles.

It explains all about taking apart cylinder head
Transaxle
Cooling System components
The required tools for this task and all other important aspects.

Engine


Removal & Installation




NOTE
Engine removal and installation requires a number of specialized tools and equipment. Make sure to read the procedure and be sure you have all of the necessary tools and equipment before beginning the procedure.



Click image to see an enlarged view
Fig. Special tools needed for engine removal and installation

CAUTION
NEVER smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury or death.

  1. Raise and safely support the vehicle.
  2. Recover the air conditioning system.
  3. Release the fuel system pressure, as outlined in the Fuel System Section.
  4. Disconnect the negative, then the positive battery cables.
  5. Drain the engine cooling system.
  6. Remove the accessory drive belt and the power steering belt, as outlined in this section.
  7. Disconnect the power steering cooler hose and drain the power steering fluid into a suitable drain pan.
  8. Remove the degas bottle.
  9. Remove the engine air cleaner and air cleaner outlet pipe.
  10. Remove the battery and the battery tray.
  11. Disconnect the battery harness electrical connector.
  12. Remove the nut and disconnect the power feed from the battery terminal.
  13. Remove the bolt and the ground wire.
  14. Detach the 2 wiring harness retainers from the cowl.
  15. Disconnect the vacuum hose from the upper intake manifold.
  16. Disconnect the upper Evaporative Emissions (EVAP) tube quick connect coupling from the purge valve.
  17. Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
  18. Detach the wiring harness retainer from the transaxle control cable bracket.
  19. Disconnect the transaxle control cable from the control lever.
  20. Detach the control cable from the bracket.
  21. Disconnect the transaxle control electrical connector.
  22. If equipped, detach the engine block heater harness retainers from the radiator support and the A/C suction tube.
  23. Remove the nut and disconnect the A/C pressure tube fitting.
  24. Discard the O-ring seal.
  25. Remove the safety clip from the A/C fitting.
  26. Disconnect the A/C suction tube fitting.
  27. Disconnect the hose from the power steering reservoir.
  28. Disconnect the fuel supply tube.
  29. Disconnect the fuel hose routing clip from the transaxle stud and position the fuel hose aside.
  30. Disconnect the 2 engine wiring harness electrical connectors.
  31. Detach the electrical connector from the LH valve cover.
  32. Remove the oil level indicator dipstick.
  33. Detach the wiring harness retainer from the RH valve cover stud bolt.
  34. Remove the bolt and the ground wire from the engine front cover.
  35. Remove the nut, the ground wire and the radio interference capacitor wire from the engine front cover stud.
  36. Loosen the exhaust flexible pipe clamp and disconnect the 2 exhaust hangers.
  37. Remove the 4 nuts and the exhaust flexible pipe and Y-pipe as an assembly.
  38. Discard the nuts and the gasket.
  39. Remove the 3 pin-type retainers, the 7 screws and the radiator splash shield.
  40. Remove the LH inner splash shield.
  41. Remove the 2 secondary latches from the transmission fluid cooler tubes.
  42. Using the special tool shown in the accompanying illustration, disconnect the transaxle cooling tubes.

    Click image to see an enlarged view
    Fig. Using the special tool shown, disconnect the transaxle cooling tubes
  43. Remove the 4 oil pan-to-transaxle bolts.
  44. Remove the 2 fasteners and the inspection cover.
  45. Remove and discard the 3 torque converter bolts.
  46. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 20 ft. lbs. (27 Nm).
  47. Remove and discard the engine oil filter.
  48. Remove the power steering cooler bracket bolt from the RH side of the subframe.
  49. For All Wheel Drive (AWD) vehicles, match mark the driveshaft for installation, then remove the 4 bolts and support the driveshaft with a piece of wire.
  50. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
  51. Remove the 2 nuts and the roll restrictor heat shield.
  52. Remove the engine roll restrictor-to-subframe through bolt.
  53. Remove and discard the power steering pressure (PSP) tube-to-pump banjo bolt and the 2 seals.
    WARNING
    Do not let the intermediate shaft rotate while it is disconnected from the gear or damage to the clockspring can occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered.
  54. Remove and discard the steering intermediate shaft bolt.
  55. Separate the steering intermediate shaft from the steering gear.
  56. Remove and discard the cotter pins and tie-rod end nuts.
  57. Remove the 3 RH subframe-to-lower bumper nuts.
  58. Remove the 3 LH subframe-to-lower bumper nuts and separate the lower bumper from the subframe.
  59. Position the special tool under the subframe assembly.

    Click image to see an enlarged view
    Fig. Position the special tool under the subframe assembly
  60. Remove the 2 nuts, 4 bolts and the subframe support brackets.

    Click image to see an enlarged view
    Fig. Remove the 2 nuts, 4 bolts and the subframe support brackets
  61. Remove the 2 front subframe nuts.
  62. Remove the 2 middle subframe nuts.

    Click image to see an enlarged view
    Fig. Remove the 2 middle subframe nuts
  63. Using the special tool, lower the subframe assembly from the vehicle.
  64. If equipped, disconnect the oil cooler coolant hoses.
  65. AWD vehicles perform the following:
    1. Remove the RH Catalyst Monitor Sensor (CMS) electrical connector.
    2. Remove the 2 RH catalytic converter support bracket bolts.
    3. Remove the 4 nuts and the RH catalytic converter. Discard the gasket and the nuts.
    4. Remove the 5 bolts and the Power Transfer Unit (PTU) support bracket.
    5. Remove the 5 bolts and the PTU.
    6. Remove the 5 bolts and the PTU.

      Click image to see an enlarged view
      Fig. Remove the 5 bolts and the Power Transfer Unit (PTU) support bracket-AWD models
  66. Position a block of wood under the transaxle. Install the special tools, or their equivalents, as shown in the accompanying illustration.

    Click image to see an enlarged view
    Fig. Position a block of wood under the transaxle. Install the special tools, or their equivalents, as shown
  67. Remove the transaxle support insulator through bolt and nut.
  68. Remove the 3 nuts, the bolt and the transaxle support insulator bracket.
  69. Remove the nut, bolt and engine mount brace.
  70. Remove the 4 engine mount nuts.
  71. Remove the 3 bolts and the engine mount.
  72. Lower the engine and transaxle assembly from the vehicle.
  73. Position the starter cable boot back and remove the 2 nuts.
  74. Detach the 2 wire terminals from the starter.
  75. Disconnect the wiring harness retainer from the starter motor stud bolt.
  76. Remove the bolt, stud bolt and the starter.
  77. Install the special tool on the LH cylinder head.

    Click image to see an enlarged view
    Fig. Install the special tool on the LH cylinder head
  78. Using the special tools and a suitable engine crane, remove the engine and transaxle from the lift table.

    Click image to see an enlarged view
    Fig. Using the special tools and a suitable engine crane, remove the engine and transaxle from the lift table
  79. Remove the 2 engine-to-transaxle bolts.
  80. Remove the 5 transaxle-to-engine bolts.
  81. Separate the transaxle from the engine.
To install:
  1. Align the transaxle to the engine.
  2. Install the 5 transaxle-to-engine bolts and tighten to 35 ft. lbs. (48 Nm).
  3. Install the 2 engine-to-transaxle bolts and tighten to 35 ft. lbs. (48 Nm).
  4. Using the special tools, position the engine and transaxle onto the lift table.
  5. Position a block of wood under the transaxle. Install the special tools, as shown.
  6. Install the starter, the bolt and the stud bolt. Tighten to 20 ft. lbs. (27 Nm).
  7. Connect the wiring harness retainer to the starter stud bolt.
  8. Attach the starter motor wire terminals and install the 2 nuts. Tighten as follows:
    1. Tighten to 9 ft. lbs. (12 Nm).
    2. Tighten to 44 inch lbs. (5 Nm).
  9. Position the starter terminal boot over the starter terminal.
  10. Raise the engine and transaxle assembly into the vehicle.
  11. Install the engine mount and the 3 bolts. Tighten to 66 ft. lbs. 90 Nm).
  12. Install the 4 engine mount nuts and tighten to 46 ft. lbs. (63 Nm).
  13. Install the engine mount brace, the nut and the bolt and tighten to 15 ft. lbs. (20 Nm).
  14. Install the transaxle support insulator bracket, the 3 nuts and the bolt. Tighten the 3 nuts to 46 ft. lbs. (63 Nm). Tighten the bolt to 59 ft. lbs. (80 Nm).
  15. Install the transaxle support insulator through bolt and nut and tighten to 129 ft. lbs. (175 Nm).
  16. For AWD vehicles, perform the following:
    1. Position the Power Transfer Unit (PTU) in place and install the 5 bolts. Tighten to 66 ft. lbs. (90 Nm).
    2. Position the PTU support bracket in place and install the 5 bolts. Tighten to 52 ft. lbs. (70 Nm).
      NOTE
      Do not tighten the 4 catalytic converter nuts at this time.
    3. Using a new gasket, install the RH catalytic converter and 4 new nuts.
    4. Install the 2 catalytic converter-to-bracket bolts.
    5. Tighten the 4 catalytic converter nuts to 30 ft. lbs. (40 Nm).
    6. Tighten the 2 catalytic converter-to-bracket bolts to 15 ft. lbs. (20 Nm).
    7. Connect the RH catalyst monitor electrical connector.
  17. If equipped, connect the oil cooler coolant hoses.
  18. Using the special tool, raise the subframe into the installed position.
  19. Install the 2 middle subframe nuts and tighten to 98 ft. lbs. (133 Nm).
  20. Install the 2 front subframe nuts and tighten to 98 ft. lbs. (133 Nm).
  21. Position the subframe support brackets in place and loosely install the 4 bolts.
  22. Install the 2 rear subframe bracket nuts and tighten to 98 ft. lbs. (133 Nm).
  23. Tighten the 4 subframe support bracket bolts to 66 ft. lbs. (90 Nm).
  24. Position the lower bumper on the subframe and install the 3 LH nuts. Tighten to 80 inch lbs. (9 Nm).
  25. Install the 3 RH lower bumper-to-subframe nuts. Tighten to 80 inch lbs. (9 Nm).
  26. Install the tie-rod ends and nuts and tighten to 35 ft. lbs. (48 Nm). Install new cotter pins.
    WARNING
    Do not let the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring can occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered, as outlined in the Chassis Electrical Section.
  27. Install the intermediate shaft onto the steering gear and install a new bolt. Tighten to 17 ft. lbs. (23 Nm).
  28. Using a new banjo bolt and 2 new seals, install the PSP tube. Tighten to 35 ft. lbs. (48 Nm).
  29. Install the engine roll restrictor-to-subframe through bolt and tighten to 76 ft. lbs. (103 Nm).
  30. Install the roll restrictor heat shield and the 2 nuts and tighten to 80 inch lbs. (9 Nm).
  31. For AWD vehicles, align the matchmarks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 bolts. Tighten the bolts to 52 ft. lbs. (70 Nm).
  32. Install the power steering cooler bracket bolt to the RH side of the subframe. Tighten to 80 inch lbs. (9 Nm).
  33. Connect the power steering cooler hose.
    NOTE
    Lubricate the engine oil filter gasket with clean engine oil before installing the oil filter.
  34. Install a new engine oil filter. Tighten to 44 inch lbs. (5 Nm) and then rotate an additional 180 degrees.
  35. Install the 3 new torque converter bolts and tighten to 41 ft. lbs. (55 Nm).
  36. Install the inspection cover and the 2 fasteners.
  37. Install the 4 oil pan-to-transaxle bolts and tighten to 35 ft. lbs. (48 Nm).
  38. Connect the 2 transmission fluid cooler tubes.
  39. Install the 2 secondary latches onto the transmission fluid cooler tubes.
  40. Install the LH inner splash shield.
  41. Install the radiator splash shield, the 3 pin-type retainers and the 7 screws.
  42. Using a new gasket, install the Y-pipe and exhaust flexible pipe assembly and 4 new nuts. Tighten to 30 ft. lbs. (40 Nm).
  43. Install the 2 exhaust hangers and tighten the exhaust clamp. Tighten to 30 ft. lbs. (40 Nm).
  44. Install the ground wire, the radio interference capacitor wire and the nut to the engine front cover stud. Tighten to 89 inch lbs. (10 Nm).
  45. Install the ground wire and bolt to the engine front cover. Tighten to 89 inch lbs. (10 Nm).
  46. Attach the wiring harness retainer to the RH valve cover stud bolt.
  47. Install the oil level indicator.
  48. Connect the 2 engine wiring harness electrical connectors.
  49. Attach the electrical connector to the LH valve cover.
  50. Connect the fuel hose routing clip to the transaxle stud.
  51. Connect the fuel supply tube.
  52. Connect the hose to the power steering reservoir.
  53. Connect the A/C suction tube fitting. Install the safety clip onto the A/C fitting.
  54. Using a new O-ring seal, connect the A/C tube fitting and install the nut. Tighten to 71 inch lbs. (8 Nm).
  55. If equipped, attach the engine block heater harness retainers to the radiator support and the A/C suction tube.
  56. Connect the transaxle control electrical connector.
  57. Attach the control cable to the bracket.
  58. Connect the transaxle control cable to the control lever.
  59. Attach the wiring harness retainer to the transaxle control cable bracket.
  60. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
  61. Connect the upper EVAP tube quick connect coupling to the purge valve.
  62. Connect the vacuum hose to the upper intake manifold.
  63. Install the ground wire and the bolt and tighten to 89 inch lbs. (10 Nm).
  64. Attach the 2 wiring harness retainers to the cowl.
  65. Connect the power feed to the battery terminal and install the nut. Tighten to 71 inch lbs. (8 Nm).
  66. Connect the battery harness electrical connector.
  67. Install the battery tray and the battery.
  68. Install the engine air cleaner and the air cleaner outlet pipe.
  69. Install the degas bottle.
  70. Install the accessory drive belt and the power steering belt, as outlined in this section.
  71. Connect the positive, then the negative battery cables.
  72. Fill the engine with clean engine oil.
  73. Fill and bleed the cooling system.
  74. Fill the power steering system.
  75. Recharge the air conditioning system.

These details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html


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