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

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Removal WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions may result in personal injury. All engines 1. Disconnect the battery ground cable (14301). For additional information, refer toSection 414-01. 2. Relieve the fuel pressure. For additional information, refer toSection 310-00A. 3. Partially drain the cooling system. For additional information, refer toSection 303-03A or Section 303-03B. 4. Remove the power steering reservoir bracket. 1. Remove the bolts. 2. Position the power steering reservoir bracket out of the way. 5. Remove the accelerator control splash shield. 1. Remove the bolts. 2. Remove the accelerator control splash shield. 6. Disconnect the fuel pressure regulator valve vacuum hose. 7. CAUTION: After disconnecting, plug the fuel lines to prevent leakage. Disconnect the fuel lines. For additional information, refer toSection 310-00A. 8. Disconnect the eight ignition coil electrical connectors. 9. Disconnect the eight fuel injector electrical connectors. 4.6L engines 10. Remove the nut and disconnect the brake booster vacuum hose and bracket 5.4L engines 11. Remove the brake booster bracket and tube. 1. Remove the nut. 2. Release and move the two hose clamps. 3. Remove the brake booster tube. All engines 12. Remove the positive crankcase ventilation (PCV) hose. 5.4L engines 13. Disconnect the water heater inlet tube hose. 1. Release and move the hose clamp. 2. Disconnect the water heater inlet tube hose and position aside.

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NOTE: Refer to the exploded view under the assembly procedure in this section. The 5.4L (3V) is a V-8 engine with the following features: Single overhead camshafts Three valves per cylinder Sequential Multi-Port Fuel Injection (SFI) Aluminum cylinder heads Cast iron, 90-degree V-cylinder block Variable Camshaft Timing (VCT) Individually chain-driven camshafts with a hydraulic timing chain tensioner on each timing chain Distributorless ignition system Electronic Returnless Fuel System (ERFS) Engine Identification Always refer to these labels when installation of new parts is necessary, or when checking engine calibrations. The engine parts often differ within a Cubic Inch Displacement (CID) family. Verification of the identification codes will make sure that the correct parts are obtained. These codes contain all the pertinent information relating to the dates, optional equipment and revisions. The Ford Master Parts Catalog contains a complete listing of the codes and their application. Engine Cylinder Identification Exhaust Emission Control System Operation and necessary maintenance of the exhaust emission control devices used on this engine are covered in the Powertrain Control/Emissions Diagnosis (PC/ED) manual. Induction System The SFI system provides the fuel/air mixture needed for combustion in the cylinders. The 8 solenoid-operated fuel injectors: are mounted in the intake manifold. meter fuel into the air intake stream in accordance with engine demand. are positioned so that their tips direct fuel just ahead of the engine intake valves. supply fuel from the fuel tank with a fuel pump mounted in the fuel tank. Valve Train The valve train operates as follows: Ball-tip hydraulic lash adjusters provide automatic lash adjustment. Roller followers ride on the camshaft lobe, transferring the up-and-down motion of the camshafts to the valves in the cylinder heads. Positive Crankcase Ventilation System

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1. Disconnect the battery ground cable (14301). For additional information, refer to Section 414-01. 2. WARNING: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before disconnecting any fuel lines or fuel system components. Relieve the fuel system pressure. For additional information, refer to Section 310-00. 3. Remove the engine air cleaner outlet tube. For additional information, refer to Section 303-03. 4. Remove the timing belt. For additional information, refer to Timing Drive Components—Timing Belt in this section. 5. Remove the vacuum hoses at the: positive crankcase ventilation (PCV) valve (6A666). throttle body (9E926). intake manifold (9424). fuel pressure sensor. 6. Disconnect the fuel charging wiring (9D930) electrical connectors at main engine connector. 7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Disconnect the fuel line. For additional information, refer to Section 303-04. 9. Remove the power steering pump (3A674) and bracket as an assembly. For additional information, refer to Section 211-02. 10. Remove the generator (GEN). For additional information, refer to Section 414-02. 11. Remove the oil level indicator tube (6754). For additional information, refer to Oil Level Indicator and Tube in this section. 12. Disconnect the heater hoses. For additional information, refer to Section 412-02. 13. Lower the vehicle. 14. Disconnect the upper radiator hose (8260) from the thermostat housing water hose connection. For additional information, refer to Section 303-03. 15. Remove the camshafts (6250). For additional information, refer to Camshaft in this section. 16. Remove the ignition coil (12029) and bracket. For additional information, refer to Section 303-07. 17. Remove the water thermostat housing. For additional information, refer to Section 303-03. 18. Disconnect the knock sensor electrical connector.

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All vehicles 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. Partially drain the cooling system. For additional information, refer toSection 303-03. 3. Remove the power steering fluid reservoir bracket. 1. Remove the bolts. 2. Position the power steering fluid reservoir bracket out of the way. 4. Remove the accelerator control splash shield. 1. Remove the bolts. 2. Remove the accelerator control splash shield. 5. Disconnect the fuel pressure regulator vacuum hose. CAUTION: After disconnecting, plug the fuel lines to prevent leakage. 6. Disconnect the fuel lines. For additional information, refer to Section 310-00. 7. Disconnect the eight fuel injector electrical connectors. 8. Disconnect the eight ignition coil electrical connectors. 9. Remove the brake booster bracket and tube. 1. Remove the nut. 2. Release and move the two hose clamps. 3. Remove the brake booster tube. 10. Remove the positive crankcase ventilation (PCV) hose. For vehicles equipped with 4.6L engine 11. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) connector, then disconnect the upper and lower EGR valve tube fitting.

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Installation All engines 1. NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation. Install new O-ring seals, as required. 2. Install the fuel injectors into the fuel injection supply manifold. 3. Position the fuel injection supply manifold and install the four bolts. 4. Connect the evaporative emission canister purge valve hose and the EGR valve vacuum hose. 4.6L engines 5. Install the exhaust manifold to EGR valve tube. 6. Connect the differential pressure feedback EGR system electrical connector. 5.4L engines 7. Install the exhaust manifold to EGR valve tube and connect the differential pressure feedback EGR system hoses. All engines 8. NOTE: 4.6L shown, 5.4L similar. Install the positive crankcase ventilation (PCV) hose. 9. Install the crankcase ventilation tube. 4.6L engines 10. Connect the brake booster vacuum tube and bracket and install the nut. 5.4L engines 11. Install the brake booster vacuum tube and bracket. 12. Connect the water heater inlet tube hose. 1. Connect the water heater inlet tube hose. 2. Compress and install the hose clamp. All engines 13. Connect the eight fuel injector electrical connectors. 14. Connect the eight ignition coil electrical connectors. 15. Connect the fuel tubes. For additional information, refer toSection 310-00A. 16. Connect the fuel pressure regulator valve vacuum hose.