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

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1. Remove door latch cover by pulling trim free of retaining clips and sliding trim away from latch. 2. Remove portion of armrest containing door lock switch and window regulator control switch (14529). Trim Panel 3. Remove screw attaching front door trim panel (23942) to front door (20124). 4. Remove two screws located at bottom of front door trim panel. 5. Disconnect the door lock switch (14028) and window regulator control switch electrical connectors. 6. Remove rear view outside mirror mounting hole cover assembly by prying at top and pulling upward to release double-sided clip. 7. Pull front door trim panel from the top to release fasteners from front door. 8. Remove front door trim panel. Disconnect lamp connector. 9. To install, reverse Removal procedure. Replace any bent or damaged fasteners. Body Side Removal and Installation 1. Remove door handle retaining clip by sliding a shop towel between handle and door trim. With tension on the cloth, pull one end of the cloth so it slides between the handle and the door trim. If handle does not come out, reverse direction. 2. Gently pry door latch bezel from door trim. 3. Pull body side trim panel from body side door. 4. To install, reverse Removal procedure. For installation of handle, install clip to handle, then push handle on to shaft to snap in place. Back Removal and Installation 1. Disconnect rear window defroster wires. 2. Remove the liftgate window garnish moulding. Refer to procedure in this section. 3. Remove screws attaching liftgate handle to liftgate and liftgate inside trim panel. 4. Using Rotunda Windshield and Moulding/Trim Removal Kit 107-R0401 or equivalent, pry pushpins retaining liftgate trim from the liftgate. 5. Remove liftgate trim. 6. To install, reverse Removal procedure. Liftgate Door Electrical Connections

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Cylinder Head Special Tool(s) Compressor, Valve Spring 303-567 (T97P-6565-AH) Spacer, Valve Spring Compressor 303-382 (T91P-6565-AH) Installer, Valve Stem Oil Seal 303-383 (T91P-6571-A) Material Metal Surface Cleaner F4AZ-19A536-RA Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP Disassembly All engines 1. On Windsor engines, remove the Camshaft Position Aligner from the camshaft (6250). Item Specification WSE-M5B392-A WSS-M2C153-H 2. CAUTION: Do not remove the camshaft before removing the roller followers. CAUTION: Place the cylinder head (6049) on a cardboard or wood surface to prevent damage to the joint face. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage. 3. NOTE: The roller followers must be reinstalled in their original locations. Record roller follower locations. Use the Valve Spring Compressor to compress the valve springs (6513), and remove the roller followers. 4. NOTE: The hydraulic lash adjusters must be installed in their original locations. Record hydraulic lash adjuster locations. Remove the hydraulic lash adjusters. 5. NOTE: Windsor engine shown; Romeo engine is similar. Use the Valve Spring Compressor to compress the valve springs. 6. CAUTION: Keep the valves and valve spring retainer keys (6518) in order so they can be installed in the same positions. NOTE: Shown without camshaft for clarity. Remove the (A) valve spring retainer keys, the (B) valve spring retainers (6514), the (C) valve springs, and the valves. 7. Remove the valve stem seals (6571). Romeo engine (4.6L) 8. NOTE: The camshaft bearing caps must be installed in their original location. Record camshaft bearing cap location. Remove the bolts, the bearing caps and the camshaft. Windsor engine (5.4L) Assembly All engines 1. CAUTION: Do not use metal scrapers or other tools to clean the cylinder head or damage to the head can occur. Use a plastic scraper and metal surface cleaner to clean the cylinder head. 2. Lubricate the camshaft journals with clean engine oil.

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Removal NOTE: 5.0L shown, 4.0L SOHC and 4.0L (push rod) similar. 1. Disconnect the idle air control (IAC) valve electrical connector. 2. Remove the IAC valve. 1. Remove the two bolts. 2. Remove the IAC valve. Discard the gasket. Installation NOTE: Install a new IAC valve gasket. 1. Install the idle air control (IAC) valve. 1. Position the IAC valve. 2. Install the two bolts. 3. Connect the IAC electrical connector.

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Removal 1. Disconnect the hood lamp harness. 1. Remove the hood insulator retainers and position the insulator away from the hood. 2. Disconnect the hood lamp harness retainers. 3. Disconnect the hood lamp electrical connector. 2. NOTE: Mark the hinge-to-hood placement to ease alignment when reinstalling the hood. Remove the hood. 1. Disconnect the windshield washer hose. 2. Remove the ground strap bolt. 3. Disconnect the hood struts. 4. Remove the four hinge-to-hood bolts and remove the hood. 3. Recover the air conditioning (A/C) system. For additional information, refer to Section 412-00. 4. Remove the lower intake manifold (9424). For additional information, refer to Intake Manifold—Lower in this section. 5. Remove the front air deflector. 1. Remove the jack handle. 2. Remove the screws. 3. Remove the air deflector. 6. Remove the radiator upper hose from the radiator. 7. Using the special tools, remove the fan blade and fan clutch. 8. Remove the fan shroud. 1. Remove the screws. 2. Lift and remove the fan shroud and fan blade, as a unit, out of the vehicle. 9. NOTE: To avoid disturbing the transmission oil cooler fittings, use a backup wrench. Disconnect the transmission fluid cooler fittings. 1. Disconnect the upper transmission fluid cooler fitting. 2. Disconnect the lower transmission fluid cooler fitting. 10. Disconnect the lower radiator hose from the radiator. 1. Pry the locking tab up and out of the slot. 2. Rotate the lower radiator hose. 3. Disconnect the lower radiator hose. 11. Disconnect the degas hose from the radiator. 1. Release the clamp. 2. Slide the hose off of the radiator fitting. 12. Remove the radiator. 1. Remove the bolts. 2. Remove the upper radiator support brackets, the jack handle and the wheel nut wrench retainers. 3. Lift the radiator off the radiator mounting insulators. 4. Remove the radiator mounting insulators. 13. Remove the accessory drive belt. For additional information, refer to Section 303-05. 14. Disconnect the generator electrical connectors. 1. B+ 2. Stator 3. Voltage regulator 15. Remove the lower bracket bolts and the generator. 16. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold. 17. Disconnect the transmission wiring harness retainers from the right cylinder head and position the harness aside. 18. Remove the bolts retaining the transmission to the engine. 19. Disconnect the bulkhead connectors. 20. Remove the ground strap retaining bolt. 21. Disconnect the degas return hose.

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Engine Front Cover If the engine front cover (6019) is being removed to check timing chain deflection, refer to Timing Chain Deflection Procedure as outlined in Section 03-00. SPECIAL SERVICE TOOL(S) REQUIRED Description Crankshaft Damper Remover Vibration Damper and Seal Replacer T82L-6316-A Vibration Damper Remover Adapter Removal 1. Remove engine (6007) from vehicle. Refer to procedure in this section. 2. Loosen drive belt tensioner (6B209) and drive belt (8620) . 3. Remove water pump pulley retaining bolts and water pump pulley (8509) . 4. Remove retaining bolts and disconnect heater water outlet tube (18663) from water pump (8501) . 5. Disconnect electrical connector at camshaft position sensor. 6. Disconnect electrical connector at crankshaft position sensor (CKP sensor) (6C315) . 7. Remove retaining bolt and disconnect radiator lower hose tube (8291) from water pump . NOTE: If the vibration damper and crankshaft pulley have to be separated, mark the vibration damper and crankshaft pulley so that they may be reassembled in the same relative position. This is important as the vibration damper and crankshaft pulley are initially balanced as a unit. NOTE: If the vibration damper is being replaced, check if the original vibration damper has balance pins installed. If so, new balance pins (6A328 or equivalent) must be installed on the new vibration damper in the same position as the original vibration damper. The crankshaft pulley (new or original) must also be installed in the same relative position as originally installed. 8. Remove crankshaft pulley (6312) and vibration damper assembly using Crankshaft Damper Remover T58P-6316-D and Vibration Damper Remover Adapter T82L-6316-B. 9. Remove four retaining bolts and remove brace from A/C bracket and P/S bracket. 10. Remove oil bypass filter (6714) . Tool Number T58P-6316-D T82L-6316-B CAUTION: The engine front cover cannot be removed without lowering the oil pan (6675) . 11. Remove oil pan . Refer to procedure in this section. CAUTION: Do not overlook the engine front cover retaining bolt located behind the oil pump and filter body (6603) . The engine front cover will break if pried upon and all retaining bolts are not removed. 12. Remove engine front cover retaining bolts. It is not necessary to remove water pump . 13. Remove engine front cover and water pump as an assembly. 14. Remove engine front cover gasket and discard. Water Pump Tightening Sequence Installation NOTE: Lightly oil all bolt and stud bolt threads before installation except those specifying special sealant. 1. Clean gasket surfaces on the engine front cover and cylinder block (6010) . If reusing the engine front cover , replace crankshaft front seal (6700) . Refer to Crankshaft Pulley and/or Damper and/or Crankshaft Front Seal in this section. 2. If a new engine front cover is to be installed: Install oil pump and filter body . Clean water pump gasket surface. Position a new water pump housing gasket (8507) on the engine front cover and install water pump . Install water pump retaining bolts. Tighten to 20-30 Nm (15-22 lb-ft). 3. Lubricate crankshaft front seal with clean engine oil XO-10W30-QSP or -DSP or equivalent meeting Ford specification ESE-M2C153-E. NOTE: Gasket and Trim Adhesive D7AZ-19B508-B or equivalent meeting Ford specification ESE-M2G52-A is recommended to hold the engine front cover gasket (6020) in position while the engine front cover is installed. 4. Position a new engine front cover gasket on the cylinder block and install the engine front cover / water pump assembly using dowels for proper alignment. 5. Install the engine front cover retaining bolts. Tighten to 20-30 Nm (15-22 lb-ft). Install the capscrew (Part No. N804841) nearest the oil bypass filter flange last, and tighten last. Apply Loctite® or equivalent to bolt prior to installation. Refer to illustration under Step 13 of removal procedure. 6. Install oil pan as outlined. 7. Install oil bypass filter . 8. Coat pulley sealing surface with clean engine oil XO-10W30-QSP or -DSP or equivalent meeting Ford specification ESE-M2C153-E. NOTE: When using silicone rubber sealer, assembly must occur within 15 minutes after sealer application. After this time, the sealer may start to setup, and its sealing effectiveness may be reduced. 9. Apply a small amount of Silicone Gasket and Sealant F1AZ-19562-A or equivalent meeting Ford specification WSE-M4G320-A2 to crankshaft keyway. 10. Position crankshaft key (6B316) in the crankshaft keyway.