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

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1. Remove spark plugs (12405). 2. Align crankshaft (6303) so number one piston is at TDC (top dead center) as indicated by timing marks. Refer to illustration. 3. Remove outer timing belt cover as outlined in this section. 4. CAUTION: If you attempt to remove timing belt or adjust tension without loosening both timing belt tensioner adjusting bolt and spring pivot bolt, you will break Camshaft Belt Tension Adjusting Tool T74P-6254-A when you attempt to relieve tension on belt. Loosen timing belt spring pivot bolt. Do not remove. 5. Hold tensioner with Camshaft Belt Tension Adjusting Tool T74P-6254-A. 6. While holding tensioner, loosen adjusting bolt and gradually release spring tension. 7. Using adjusting tool, rotate tensioner, against spring pressure, as far clockwise as possible. While holding, tighten adjusting bolt to hold tensioner away from belt. 8. Remove timing belt. Camshaft Timing Belt, 2.3L I-4 Installation NOTE: Care must be taken during timing belt installation to prevent damage to the inner timing cover.

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1. NOTE: When the battery has been disconnected or reconnected, volatile memory information will be lost. The affected systems will have to be programmed by the technician or customer. These systems include: radio station presets, clock settings, seat memory, mirror memory, window memory and customer input keyless, window memory and customer input keyless entry codes. Disconnect the battery ground cable. For additional information, refer to Section 14-01. 2. Drain the cooling system. For additional information, refer to section 03-03. 3. Remove the engine cover (covering the throttle body). 4. Disconnect the crankcase ventilation tube and the idle air control valve inlet tube from the air cleaner outlet tube. Remove the air cleaner outlet tube. 5. WARNING: THE FUEL SUPPLY LINES ON VEHICLES EQUIPPED WITH FUEL INJECTED ENGINES REMAIN PRESSURIZED FOR LONG PERIODS AFTER ENGINE SHUT DOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED PRIOR TO FUEL SYSTEM SERVICE, TO PREVENT POSSIBLE INJURY. Connect the Multiport Fuel Injection (MFI) Fuel Pressure Gauge (T80L-9974-B) to the fuel pressure relief valve on the fuel supply manifold. Open the manual valve on the gauge to relieve the fuel system pressure. Once the pressure is relieved, close the valve and remove the gauge. 6. Remove the locking clip from the pressure and return fuel line spring lock couplings. Using the spring lock coupling disconnect tools (D87L-9280-A for 3/8-inch line, D87L-9280-B for 1/2-inch line) on the couplings. Push the tool into the cage opening to release the female fitting from the garter spring. Remove the tool and pull the male coupling and fitting apart. Install protective caps over the lines and the fuel rail. 7. Disconnect the upper radiator hose from the water outlet connection and position it out of the way. 8. Disconnect the accelerator cable and the speed control actuator cable from the throttle body and the locator. Remove the screws retaining the cables to the accelerator cable bracket and position the cables out of the way. 9. Disconnect the wiring connectors from the throttle position sensor (TP), idle air control valve (IAC) and the engine coolant temperature sensor (ECT). Disconnect the wiring connectors from the LH fuel injectors and the two wiring locators from the fuel rail. Position the harness out of the way. 10. CAUTION: Do not pull directly on the ignition wires, the wires could separate from the connectors inside the boots. Disconnect the ignition wires from the LH spark plugs and position them out of the way. Refer to Section 03-07. 11. Remove the bolts retaining the spark plug wiring harness bracket to the intake manifold and the generator. Disconnect the ignition wires from the locators and remove the bracket. 12. Remove the serpentine drive belt from the generator pulley. Refer to Section 03-05. 13. Remove the generator retaining bolts and position it out of the way. 14. Remove the PCV valve and tube. 15. Disconnect the wiring connectors from the water temperature indicator sender unit and the EGR vacuum regulator solenoid. Disconnect the RH fuel injector connectors and harness locators from the fuel rail. Position the harness out of the way. 16. CAUTION: Do not pull directly on the ignition wires, the wires could separate from the connectors inside the boots. Disconnect the ignition wires from the RH spark plugs and position them out of the way. For additional information, refer to Section 03-07. 17. Disconnect the vacuum line from the fuel vapor storage canister purge valve. Disconnect the heater hose from the rear of the intake manifold. 18. Disconnect the main vacuum hose from the rear of the intake manifold. Disconnect the hose from the fuel vapor storage canister purge valve. 19. Disconnect the EGR tube nut from the EGR valve. 20. Disconnect the vacuum hose from the EGR valve. Remove the EGR valve and gasket. 21. Remvoe the water outlet connection housing. 22. Remove the intake manifold. Remove and discard the intake manifold gaskets.

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1. Remove the front door trim panel and watershield from the front door. Refer to Section 01-05A or Section 01-05B. 2. Disconnect front door latch actuating rod (22152) from lock cylinder. 3. Remove attaching screws from front door latch remote control and link (21818). Remove front door latch remote control and link from front door. 4. Disconnect front door latch control cylinder rod (22134) from front door latch remote control and link. 5. Disconnect front door latch remote control link. For installation, follow removal procedures in reverse order. Front Door Latch Installation, Aerostar Liftgate, Aerostar Removal and Installation 1. Open liftgate and remove liftgate door trim panel and liftgate handle, if so equipped. 2. Disconnect liftgate latch release rod from control assembly. 3. Remove three latch retaining screws and remove luggage compartment door lock mechanism cover (43243) and latch from liftgate. 4. On vehicles equipped with liftgate ajar warning switch, pull latch slightly away from liftgate and disconnect electrical wire harness from the latch. To install, reverse Steps 1 through 4. Tighten liftgate handle retaining screws to 4-8 Nm (36-70 lb-in). Liftgate Latch, Aerostar

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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.