Thursday, March 15, 2012

How To Replace Engine on Ford Expedition and Lincoln Navigator?


The procedure is similar for both ford and Lincoln car models:-----

The details to replace Complete engine  is as follows:---

 Engine
REMOVAL & INSTALLATION:-----

  1. Disconnect the negative battery cable.
  2. Drain and the engine coolant.
  3. Recover A/C system refrigerant.
  4. Remove the RH and LH headlamp assemblies.
  5. Remove the front fascia.
  6. Remove the cooling fan shroud.
  7. Remove the 2 hood latch assembly bolts.
  8. Disconnect the cable position retainers and position the hood latch assembly aside.
  9. Remove the pushpin and move the air deflector aside.
  10. Remove the transmission cooler tube secondary latches.
  11. Using the quick disconnect tool 307-309, disconnect the transmission fluid cooler tubes from the transmission fluid cooler hoses.
  12. Remove the 2 condenser inlet fitting nuts and disconnect the 2 fittings.Expedition vehicles
  13. Disconnect the horn electrical connector. Navigator vehicles
  14. Disconnect the electrical connector and remove the bolt and the horn assembly All vehicles
  15. Disconnect the ambient temperature sensor electrical connector.
  16. Remove the 6 radiator support bolts and remove the cooling module from the vehicle. 

    image
    Fig. Expedition & Navigator Cooling Module and related parts
  17. Remove the bypass tube.
  18. If servicing the engine on a four wheel drive (4WD) vehicle, remove the front drive shaft
  19. Remove the starter.
  20. Remove the accessory drive belt.
  21. Remove the nut and the ground cable and disconnect the wiring harness retainer.
  22. Disconnect the powertrain control module (PCM) electrical connector.
  23. Remove the bolt and the ground cable.
  24. If equipped, disconnect the 2 auxiliary heat coolant hose quick connect couplings.
  25. Disconnect the heater coolant hose quick connect coupling.
  26. Disconnect and remove the 2 heater coolant hose quick connect couplings.
  27. Remove the clip and disconnect the degas bottle coolant outlet hose quick connect coupling.
  28. If equipped, disconnect the block heater electrical connector.
  29. If equipped, disconnect the block heater wiring harness retainers.
  30. Disconnect the wiring harness position retainer from the power steering pump stud bolt.
  31. Disconnect the wiring harness position retainer and the engine oil pressure (EOP) switch electrical connector and position the wiring harness aside.
  32. Remove the nut and the power steering pressure tube support bracket.
  33. Remove the 2 bolts, the stud bolt and position the power steering pump aside.
  34. Disconnect the starter wiring harness retainer.
  35. Remove the nut and remove the starter wiring harness and transmission fluid cooler tube support brackets from the nut.
  36. Disconnect the wiring harness position retainer and the crankshaft position (CKP) sensor and A/C compressor electrical connectors
  37. Remove the 3 stud bolts and position the A/C compressor aside.
  38. Remove and discard the oil filter.
  39. Remove the bolts and the flexplate inspection cover.
  40. Remove the cylinder block opening cover.
  41. Remove the torque converter-to-flexplate nuts.
    NOTE
    The upper 2 transmission-to-engine bolts will be removed later.
  42. Remove the lower 5 transmission-to-engine bolts.
  43. Disconnect the heated exhaust gas oxygen sensor (HO2S) electrical connectors.
  44. Remove the 4 exhaust manifold flange nuts.
    WARNING
    Only use hand tools when removing the engine support insulator through bolts or damage to the engine support insulator-to-cylinder block bracket can occur.
  45. Remove the RH and LH engine support insulator through bolts.
  46. Remove the upper 2 transmission-to-engine bolts and install the special tool.
  47. Using a suitable floor crane, remove the engine assembly from the vehicle
To install:
  1. Using a suitable floor crane, position the engine assembly into the vehicle.
  2. Install the LH and RH engine support insulator bolts.
  3. Apply Threadlock 262 to the bolt threads prior to installation and tighten to 258 ft. lbs. (350 Nm).
    NOTE
    Align the engine-to-transmission dowels before installing the engine-to-transmission bolts.
  4. Install the lower 5 transmission-to-engine bolts and tighten to 35 ft. lbs. (48 Nm).
  5. Install the 4 exhaust manifold-to-catalytic converter nuts and tighten to 30 ft. lbs. (40 Nm).
  6. Connect the heated exhaust gas oxygen sensor (HO2S) electrical connectors.
  7. Install new torque converter-to-flexplate nuts and tighten to 26 ft. lbs. (35 Nm).
  8. Install the cylinder block opening cover.
  9. Install the flexplate inspection cover and the bolts to 26 ft. lbs. (35 Nm).
  10. Install the upper 2 transmission-to-engine bolts and tighten to 35 ft. lbs. (48 Nm).
  11. Position the starter wiring harness and transmission fluid cooler tube support brackets and tighten the retaining nut to 89 inch lbs. (10 Nm).
  12. Connect the starter wiring harness retainer.
  13. Install a new oil filter.
  14. Position the power steering pump and install the stud bolt and the 2 bolts. Tighten to 18 ft. lbs. (25 Nm).
  15. Connect the wiring harness position retainer to the power steering pump stud bolt.
  16. Connect the wiring harness position retainer and the engine oil pressure (EOP) switch electrical connector.
  17. Install the power steering pump support bracket and the nut. Tighten the nut to 89 inch lbs. (10 Nm).
  18. If equipped, connect the block heater wiring harness retainers.
  19. If equipped, connect the block heater electrical connector.
  20. Position the A/C compressor and install the 3 stud bolts. Tighten to 18 ft. lbs. (25 Nm).
  21. Connect the wiring harness position retainer and the crankshaft position (CKP) sensor and A/C compressor electrical connectors.
  22. Install the clip and connect the degas bottle coolant outlet hose quick connect coupling.
  23. Position the ground cable and install the bolt. Tighten to 89 inch lbs. (10 Nm).
  24. Position the 2 heater coolant hoses and connect the quick connect couplings.
  25. Connect the heater coolant hose quick connect coupling.
  26. If equipped, connect the 2 auxiliary heat coolant hose quick connect couplings.
  27. Connect the powertrain control module (PCM) electrical connector.
  28. Connect the wiring harness retainer and ground cable and install the nut. Tighten to 89 inch lbs. (10 Nm).
  29. Install the accessory drive belt.
  30. Install the bypass tube.
  31. Install the cooling module.
  32. If servicing the engine on a four wheel drive (4WD) vehicle, install the front drive shaft.
  33. Install the starter.
  34. Install the hood.
  35. Fill the crankcase with oil.
  36. Fill and bleed the engine cooling system.
  37. Fill and bleed the power steering system.
  38. Evacuate, leak test and charge the refrigerant 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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