Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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All vehicles 1. Remove the valve cover. For additional information, refer to Section 303-01C. 2. Disconnect the fuel injector electrical connector. Two-piece head tube 3. NOTE: Some engines may have been updated with a new two-piece crankcase-to-head tube. If the crankcase-to-head tube has been updated it will have a hex head. If the high-pressure oil rail has a hex head, remove the crankcase-to-head tube assembly. Remove and discard the O-ring seals. All vehicles 4. NOTE: Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support the components. NOTE: Use a tool like the KD Tool #58965 or Lisle T30 to avoid interference with the evaporator case. Remove the bolts and the high-pressure oil rail. One-piece head tube 5. NOTE: The rings on the crankcase-to-head tube are to be used to pry the tube assembly from the branch tube assembly or the oil rail assembly. Remove the crankcase-to-head tube. Remove and discard the O-ring seal. Two-piece head tube 6. CAUTION: Use care not to deform the lower crankcase-to-head tube during removal. If the tube is damaged, a new tube must be installed. NOTE: Use a shop towel and metal brake parts cleaner to remove the oil residue prior to removing. If the updated crankcase-to-head tube separated, using a pair of soft jawed pliers, remove the lower crankcase-to-head tube. All vehicles 7. CAUTION: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur. Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier. 8. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug. 9. CAUTION: Failure to account for all snap rings or pieces prior to placing the vehicle back in service can cause engine damage. A missing snap ring can be ingested into the lube oil system, causing severe engine damage. CAUTION: To prevent engine damage, do not use air tools to remove the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole. NOTE: There is no need to drain the fuel rail. NOTE: If engine coolant is found in the combustion chambers, it may be necessary to install a new injector sleeve. For additional information, refer to Fuel Injector Sleeve in this section. NOTE: Use a tool like Snap-On SDMT440 torx to avoid damaging the fuel injector plastic and to avoid interference with the evaporator case. Remove the bolt, fuel injector hold-down clamp and fuel injector. Installation One-piece head tube

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-00. 2. If servicing the radiator, drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section. 3. Remove the parts in the order indicated in the following illustrations and tables. 4. To install, reverse the removal procedure. If servicing the radiator, fill the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section. Item 9: Lower Degas Bottle Hose Removal Note 1. Remove the lower degas bottle hose from the clip on the radiator lower fan shroud. Item 10: A/C Tube Removal Note 1. On 4.6L engines, detach the A/C tube from the retainers. Item 11: Transmission Cooler and A/C Tubes Removal Note 1. Disconnect the transmission cooler tubes. Remove the safety retainers from the transmission cooler tubes. Using the special tool, disconnect the quick coupler. If equipped, loosen and remove the screw clamp from the hose. 2. Remove the A/C tube brackets from the engine front cover. Item 12: Radiator Fan Shroud Screw Removal Note 1. Not all vehicles will have these radiator fan shroud screws. If vehicle is equipped with these screws, please discard them. Item 15: Cooling Fan Removal Note 1. CAUTION: Cardboard must be placed against the radiator when removing the cooling fan. Failure to follow these procedures can result in damage to the vehicle. Place a piece of cardboard against the radiator to prevent damage while removing the cooling fan. 2. Using the special tools, remove the fan blade and the clutch assembly. Item 17: Radiator Lower Fan Shroud Removal Note 1. Remove the power steering tube from the clip on the radiator lower fan shroud. Item 19: Radiator Bracket Bolt Removal Note 1. If necessary, remove the radiator brackets. Item 21: A/C Condenser Support Bracket Bolt Removal Note 1. If necessary, remove the condenser brackets. Item 22: Radiator Removal Note 1. NOTE: It will be necessary to lift the radiator assembly up off the mounts and set it on the frame in order to separate the A/C condenser from the radiator. NOTE: RH side shown, LH side similar. Remove the radiator up off the mounts and set it on the frame. 2. Remove the left inner air deflector from the A/C condenser. 3. Remove the right inner air deflector from the A/C condenser.

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Removal All vehicles 1. Remove the wheel and tire assembly. For additional information, refer to Section 204-04. 2. NOTE: Caliper is removed for clarity. Position aside the front disc brake caliper and anchor plate (2B292). 1. Remove the two front disc brake caliper anchor plate bolts. 2. Remove the front disc brake caliper anchor plate and position aside. 3. NOTE: Carry out this step for F-250 and F-350 4×4 SRW vehicles. Remove the rotor. 4. NOTE: Carry out this step for DRW vehicles. NOTE: If excessive force must be used during brake rotor removal, the brake rotors should be checked for lateral runout prior to installation. For additional information, refer to Section 206-00. Remove the eight hub extender nuts, the hub plate and the rotor. 1. Remove the eight hub plate nuts. 2. Remove the hub plate. 3. Remove the rotor. 5. Remove the hub lock. 1. Remove the retainer ring. 2. Pull outward and remove the hub lock. 6. Remove the axle shaft thrust washers. 1. Remove the snap ring. 2. Remove the three thrust washers. Vehicles equipped with ABS 7. CAUTION: Do not remove the ABS sensor from the bearing. Disconnect the ABS wheel sensor harness. 1. Disconnect the connector. 2. Disconnect the harness routing clips. All vehicles 8. NOTE: The wheel hub and bearing is a slip fit design and should not require a puller to remove it. Remove the wheel hub and bearing. 1. Remove the four lock nuts. 2. Remove the wheel hub and bearing.

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NOTE: This procedure covers the removal and installation of the LH and RH front wheel driveshaft and joints. However, in the case of 1.8L engines, a halfshaft (3A329) is placed between the transaxle and the (outboard) front wheel driveshaft and joint (3B436) . For removal and installation procedures of either the two-piece RH front wheel driveshaft and joint assembly or the RH front wheel driveshaft and joint outboard half only, refer to the appropriate procedures in this section. Removal 1. Raise and support the vehicle. 2. Remove the lug nuts (1012) and the front wheel and tire assembly. 3. Remove the front fender splash shield bolts and the front fender splash shields (16103) . 4. Use a small cape chisel to carefully raise the staked portion of the front axle wheel hub retainer (3B477) . 5. Remove the front axle wheel hub retainer and discard it. 6. Remove the cotter pin and the tie rod end nut from the tie rod end (3A130) . Discard the cotter pin. 7. Use an appropriate tie rod end remover to separate the tie rod end from the front wheel knuckle (3K186) . 8. Remove the ball joint bolt and the ball joint bolt nut. 9. Carefully pry down on the front suspension lower arm (3078) to separate the front suspension lower arm ball joint (3050) from the front wheel knuckle . 10. Pull outward on the front wheel knuckle (3K185) . Carefully pull the front wheel driveshaft and joint from the front wheel knuckle and position it aside. 11. NOTE: Removal of the LH front wheel driveshaft and joint (3B437) requires removal of the rear engine support (6A023) to allow access with a pry bar. If the LH front wheel driveshaft and joint is being removed, continue with step 11. If the RH front wheel driveshaft and joint is being removed, continue with step 15. Support the transaxle with a transaxle jack or equivalent. 12. Remove the four transaxle mount-to-rear engine support nuts. 13. Remove the two rear engine support nuts at the rear of the rear engine support . 14. While supporting the rear of the rear engine support remove the two rear engine support bolts. Remove the rear engine support .

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All vehicles 1. Raise and support the vehicle. For additional information, refer to Section 100-02. 2. NOTE: The rear wheels and brake drums/calipers must be removed to prevent brake drag during drive pinion bearing preload adjustment. Remove the wheel and tire assembly. For additional information, refer to Section 204-04. Vehicles with drum brakes 3. Remove the rear brake drums. For additional information, refer to Section 206-02. Vehicles with disc brakes 4. Remove the rear disc brake caliper. For additional information, refer to Section 206-04.  Wire the rear disc brake caliper aside. 5. Remove the rear brake disc. 6. Mark the driveshaft flange and pinion flange for correct alignment during installation. 7. Remove the four driveshaft bolts. 8. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. Ne ver hammer on the driveshaft or any of its components to disconnect the yoke from the flange. Pry only in the area shown with a suitable tool to disconnect the yoke from the flange. Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the rear axle pinion flange. Position the driveshaft out of the way. 9. Install an inch-pound torque wrench on the pinion nut and record the torque required to maintain rotation of the pin ion through several revolutions. 10. CAUTION: After removal of the pinion nut, discard it. A new nut must be used for installation. Using the special tool, hold the pinion flange and remove the pinion nut. 11. Mark the pinion flange in relation to the drive pinion stem to make sure of correct alignment during installation. 12. Using the special tool, remove the pinion flange. Installation All vehicles 1. Lubricate the pinion flange splines with rear axle lubricant. 2. NOTE: Disregard the scribe marks if a new pinion flange is being installed. Align the pinion flange with the drive pinion shaft.