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

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1. Disconnect the brake booster vacuum check valve (1) from the brake booster. 2. If the vacuum check valve (1) needs to be separated from the vacuum hose (3), release and reposition the clamp (2) on the vacuum hose (3) and remove the check valve (1) from the hose (3). 3. If replacing the vacuum check valve (1), remove the grommet (4) from the brake booster and discard the grommet. 4. If removing the vacuum hose (2), take note of the vacuum hose routing then disconnect from the engine intake manifold connection (3) by releasing tension on the vacuum hose clamp (1) and sliding the vacuum hose (2) off the intake manifold connection (3). Installation Procedure Important: A small amount of denatured alcohol can be used as an assembly aid when installing the vacuum check valve and/or grommet. Do NOT use soap. 1. If the vacuum hose (2) was removed, install the vacuum hose into position on the vehicle as noted prior to removal, then connect the vacuum hose (2) to the engine intake manifold connection (3) and secure with the vacuum hose clamp (1). 2. If the vacuum check valve (1) is being replaced, install a NEW grommet (4) to the brake booster. 3. If the vacuum check valve (1) was separated from the vacuum hose (3), install the check valve (1) to the vacuum hose (3). Install and secure the clamp (2) into position on the hose (3). 4. Connect the brake booster vacuum check valve (1) to the brake booster.

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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.

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1. NOTE: Removal and installation of the instrument panel (04320) is best accomplished by two people. Refer to Section 18-01 for wiring routing and connection locations. Position front wheels in the straight-ahead position. 2. Disconnect battery ground cable (14301). Refer to Section 14-01. 3. Unsnap and remove instrument panel insulator (046A24) from instrument panel reinforcement (04545). 4. On floor shift models, remove console finish panel (04567) as outlined. 5. Remove two screws retaining instrument panel steering column cover (04459) to instrument panel. Remove instrument panel steering column cover by unsnapping from instrument panel. 6. Remove two screws retaining instrument panel brace below steering column. Disconnect courtesy lamp socket. Remove instrument panel brace. 7. On vehicles with manual A/C-heater, remove main wiring (14401) electrical connectors and vacuum hose harness (19C827) from A/C evaporator case (19897) and blower motor (18527). Manual A/C-Heater Disconnect

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1. Disconnect wiring connector retaining engine compartment lamp. 2. Mark position of hood hinges (16796) and remove hood (16612) . 3. Drain engine cooling system. Refer to Section 03-03. 4. Disconnect battery ground cable (14301) . 5. Remove cowl top vent panel (022A68) . Refer to Section 01-02. 6. Disconnect generator and voltage regulator wiring assembly. 7. Remove engine air cleaner (ACL) (9600) and outlet tube. 8. Disconnect upper radiator hose (8260) from engine. 9. Disconnect heater water hoses (18472) . 10. Disconnect heater hose bracket bolt on left side of engine. 11. Disconnect oil cooler inlet tube (7A030) and oil cooler tube (7A031) using Oil Cooler Line Disconnect Tool T86P-77265-AH. 12. Discharge A/C system. Refer to Section 12-00. 13. Disconnect manifold and tube assembly from A/C compressor. 14. Remove accelerator cable bracket (9723) . 15. Relieve fuel pressure and disconnect fuel supply line. Refer to Section 10-01. 16. Disconnect fuel return line. 17. Disconnect ground wire assembly. 18. Disconnect PCM wiring assembly. 19. Disconnect engine control sensor wiring (12A581) . 20. Remove bolt retaining electrical harness bracket. 21. Disconnect vacuum hoses. 22. Disconnect bulkhead connector. 23. Disconnect transaxle pressure switches. 24. Disconnect throttle valve control actuating cable (7F042) . 25. Raise vehicle on hoist. Refer to Section 00-02. 26. Position drain pan beneath vehicle oil pan (6675) . 27. Drain engine oil. 28. Remove oil bypass filter (6714) . 29. Position drain pan away from vehicle. 30. Remove wheel and tire assemblies. 31. Remove brake calipers and position out of way. 32. Disconnect electrical connector at anti-lock brake wheel sensor. 33. Disconnect heated oxygen sensors (HO2S) (9F472) . 34. Remove dual converter Y pipe retainer bolts. 35. Install Exhaust Connector Holder Tool T94T-6000-AH and remove dual converter Y pipe (5F250) .

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ISSUE Some 2005-2008 F-Super Duty 250/350 vehicles equipped with a 5.4L 3V or 6.8L 3V engine may experience premature automatic shut off of the fuel fill nozzle, or repeated fuel shut off at the fuel station delivery nozzle with malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0191. Vehicles operated in muddy or dusty environments can encounter a dirt clogged carbon canister system. More specifically, the carbon canister’s vent, fresh air box, and filters become clogged with dirt from operating in such environments. SERVICE PROCEDURE Inspect the vehicle canister system and if it found to be dirt clogged then continue with this TSB. NOTE IF THE VEHICLE’S CANISTER SYSTEM IS NOT DIRT CLOGGED, THEN PROCEED WITH NORMAL DIAGNOSTICS AND DO NOT CONTINUE WITH THIS TSB. Vehicles with Pickup Boxes: 1. Replace the carbon canister assembly with a canister built after 10/1/2006. This canister has a revised internal filter media, and went into production on 10/1/2006. The date code is on a black sticker located on the carbon canister assembly. 2. Relocate the fresh-air intake port to a more protected location using the fresh air hose kit, for pickup applications only. 3. Replace fuel cap assembly if the vehicle was built before 5/16/2007. Vehicles with Pickup Box Removed or Chassis Cab: 1. Replace the carbon canister assembly with a canister built after 10/1/2006. This canister has a revised internal filter media, and went into production on 10/1/2006. The date code is on a black sticker located on the carbon canister assembly. 2. Relocate the fresh-air intake port to a more protected location using QVM bulletin Q-132 at the body builder’s website – https://www.fleet.ford.com/truckbbas/index.htm for fresh air intake routing recommendations. 3. Replace fuel cap assembly if the vehicle was built before 5/16/2007.