2009 Ford F-250 Thermostat 6.4L Diesel Engine Removal

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Filed Under (Ford) by admin on 07-05-2011

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Removal NOTE: Removal of the vertical EGR cooler is not required to service the thermostats. 1. Remove the upper cooling fan shroud. For additional information, refer to Cooling Fan Shroud — 6.4L Diesel, Upper in this section. 2. Remove the degas bottle. For additional information, refer to Degas Bottle — 6.4L Diesel in this section. 3. Using a mirror, find the end of the upper radiator hose spring clip. Remove the spring clip, disconnect the upper radiator hose from the thermostat housing and position the upper radiator hose aside. 4. Remove and discard the nut and the vertical EGR cooler lower clamp. 5. Remove the bolt and the vertical EGR cooler lower bracket. 6. NOTE: Vertical EGR cooler removed from art for clarity. Disconnect the wiring from the heater return tube. 7. Remove the 2 bolts and position out the LH heater return tube. • Remove and discard the O-ring seal. 8. NOTE: The 6.4L diesel engine uses 2 thermostats. Remove the 4 bolts, the collar and the thermostat housing. • Lift the bottom of the collar up and rotate toward the engine to remove. 9. NOTICE: If the thermostats are contaminated with engine oil, new thermostats must be installed. Reusing a thermostat that has been exposed to engine oil may result in engine overheating. Remove the thermostats and the gasket from the thermostat housing. • Discard the gasket. Installation 1. Install a new gasket and the thermostats into the thermostat housing. 2. Install the thermostat housing, the collar and the 4 bolts. • Tighten to 13 Nm (115 lb-in). 3. NOTE: Vertical EGR cooler removed from art for clarity. NOTE: Install a new O-ring seal. Install the LH heater return tube and the 2 bolts. • Tighten to 13 Nm (115 lb-in). 4. Connect the wiring to the heater return tube. 5. Position the lower vertical EGR cooler bracket and loosely install the bolt. 6. Install a new vertical EGR cooler lower clamp. Tighten the clamp nut in 3 stages. • Stage 1: Tighten the nut to 10 Nm (89 lb-in). • Stage 2: Loosen the nut 720 degrees (2 complete turns). • Stage 3: Tighten the nut to 8 Nm (71 lb-in). 7. Tighten the lower EGR cooler bracket bolt. • Tighten to 62 Nm (46 lb-ft). 8. Connect the upper radiator hose to the thermostat housing. Install the spring clip. • Verify the spring clip is correctly seated. 9. Install the degas bottle. For additional information, refer to Degas Bottle — 6.4L Diesel in this section. 10. Install the upper cooling fan shroud. For additional information, refer to Cooling Fan Shroud — 6.4L Diesel, Upper in this section.

2000 Hyundai Accent L Hatch Back Cylinder Head Assembly Removal and Installation

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Filed Under (Hyundai) by admin on 04-05-2011

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1. 2. 3. 4. 5. Drain the coolant and disconnect the upper radiator hose. Remove the breather hose (between the air cleaner and the rocker cover). Remove the air-intake hose. Remove the vacuum hose, fuel hose and coolant hose. Remove the cables from the spark plugs. The cables should be removed by holding the boot portion. Remove the ignition coil. Remove the surge tank. Remove the intake manifold. Remove the heat protector and exhaust manifold assembly Remove the coolant pump pulley and the crankshaft pulley. Remove the timing belt cover. 6. 7. 8. 9. 10. 11. Zoom Sized for Print 12. Move the timing belt tensioner pulley toward the coolant pump and temporarily secure it. 13. Remove the timing belt. 14. Remove the rocker cover. 15. Remove the cylinder head assembly. The cylinder head bolts should be removed using Special Tool, Cylinder Head Bolt Wrench (09221-21000), in the sequence as shown in the illustration. 16. Remove the gasket pieces from the cylinder block top surface and cylinder head bottom surface. NOTE: 1. Make sure that the gasket pieces do not fall in to the engine. INSPECTION 1. Check the cylinder head for cracks, damage and coolant leakage. 2. Remove scale, sealing compound and carbon deposits completely. After cleaning oil passages, apply compressed air to make certain that the passages are not clogged. 3. Check the cylinder head surface for flatness using a straight edge in the direction of A, B, …as shown. If flatness exceeds service limit in any direction, replace the cylinder head, or lightly machine the cylinder head surface. Cylinder head flatness Standard value: Less than 0.03 mm (0.0012 inch) Limit: 0.08 mm (0.0031 inch) REASSEMBLY 1. Clean all gasket surfaces of the cylinder block and the cylinder head. 2. Install a new cylinder head gasket onto the cylinder head assembly. Do not apply sealant to the gasket and do not reuse the old cylinder head gasket.

2003 Ford F-Super Duty 250-550 Intake Manifold Removal All vehicles

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Filed Under (Ford) by admin on 03-04-2011

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1. Remove the auxiliary battery. For additional information, refer to Section 414-01. 2. Remove the air cleaner assembly. For additional information, refer to Section 303-12. 3. Remove the cooling fan-blade, clutch and shroud, 6.0L diesel engine. For additional information, refer to Section 303-03. 4. Remove the coolant reservoir. For additional information, refer to Section 303-03. 5. Remove the upper radiator hose. 6. NOTE: Engine side shown, charge air cooler (CAC) side similar. Remove the turbocharger-to-charge air cooler pipe. 7. NOTE: Engine side shown, charge air cooler side similar. Remove the charge air cooler-to-engine pipe. Vehicles with dual generators 8. Remove the accessory drive belt. 9. Remove the bolt and the accessory drive belt tensioner. 10. Remove the accessory drive belt. 11. Remove the bolts, bracket and accessory drive belt idler pulley. 12. Remove the bolts and the accessory drive belt tensioner. 13. Disconnect the wire retainer, generator electrical connector and B+ wire. 14. Remove the bolts and the generator with mounting bracket. Vehicles with single generator 15. Remove the accessory drive belt. All vehicles 16. Position the boot back and disconnect the generator B+ wire and electrical connector. 17. Remove the three bolts and the generator. 18. Remove the turbocharger and the turbocharger pedestal. For additional information, refer to Section 303-04F. 19. Remove the bolts and position the heater hose tube aside. ? Remove and discard the O-ring. 20. Disconnect the manifold absolute pressure (MAP) sensor hose. 21. Disconnect the engine coolant vent hose. 22. Remove the fuel injector control module. For additional information, refer to Section 303-14C. 23. Disconnect the wiring retainer, injector pressure regulator and injector control pressure (ICP) sensor electrical connector. 24. Disconnect the exhaust gas recirculation (EGR) valve electrical connector. 25. Disconnect the oil pressure sensor electrical connector. 26. Disconnect the oil temperature sensor electrical connector.

1994 Lincoln Town Car Oil Pan and Oil Pump Screen Cover and Tube Removal

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Filed Under (Lincoln) by admin on 11-03-2011

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1. Disconnect battery ground cable. 2. Remove air cleaner outlet tube. 3. Drain cooling system and remove fan blade and fan shroud . Refer to Section 03-03. 4. Relieve fuel system pressure and disconnect fuel lines. Refer to Section 10-01. 5. Remove upper radiator hose. 6. Remove windshield wiper governor and support bracket. Refer to Section 01-16. 7. Discharge air conditioning system. Refer to Section 12-00. 8. Disconnect A/C compressor to condenser discharge line at A/C compressor and remove bolt retaining hose assembly to RH ignition coil bracket. 9. Remove 42-pin engine harness connector from retaining bracket on power brake booster . 10. Disconnect 42-pin connector and transmission harness connector. 11. Disconnect throttle valve control actuating cable from throttle body . 12. Disconnect heater water hose. 13. Remove nut retaining ground strap to RH cylinder head . 14. Remove upper stud and lower bolt retaining heater water hose to RH cylinder head and position out of way. 15. Remove heater blower motor switch resistor. 16. Remove bolt retaining RH front engine support insulator to front sub-frame . 17. Raise vehicle on a hoist. Refer to Section 00-02. 18. Drain engine oil. 19. Remove the lower splash shield. NOTE: Two through bolts for LH front engine support insulator and one through bolt for RH front engine support insulator . 20. Remove front engine support insulator through bolts. 21. Remove EGR valve to exhaust manifold tube nut from RH exhaust manifold and remove EGR valve to exhaust manifold tube . 22. Disconnect three-way catalytic converter from RH and LH exhaust manifold . 23. Lower exhaust and wire to crossmember in positions shown. 24. Position a screw-type jackstand and a block of wood under oil pan , rearward of oil drain hole. 25. Raise engine approximately 100mm (4 inches). 26. Insert two wood blocks approximately 60-70mm (2.5-2.75 inches) thick under each front engine support insulator. 27. Lower engine onto wood blocks and remove jack from under oil pan .

1997 Ford F-250/350/Super Duty Engine Front Cover Removal

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Filed Under (Ford) by admin on 06-03-2011

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Crankshaft front seal replacement is recommended whenever the engine front cover (6019) has been removed. 1. Disconnect battery ground cable (14301). Drain crankcase. 2. Drain cooling system. Refer to Section 03-03. 3. Remove drive belts (8620). Refer to Section 03-05. 4. Remove bolts attaching fan shroud (8146) to radiator (8005). 5. Remove fan blade (8600) from fan clutch (8A616) and remove fan shroud. 6. Remove fan clutch and water pump pulley (8509) from water pump (8501). 7. Disconnect upper radiator hose (8260) and lower radiator hose (8286) at engine (6007). Disconnect transmission oil cooler lines at radiator. 8. Remove upper radiator support bracket and remove radiator. 9. Remove generator pivot and attaching bolts. Remove generator (GEN) (10300) from generator mounting bracket (10153) and generator adjusting arm (10145). 10. Remove two bolts attaching generator adjusting arm to water pump and generator mounting bracket and remove generator adjusting arm. 11. Remove air pump pivot and attaching bolts. Remove secondary air injection pump (AIR pump) (9A486) from generator mounting bracket. 12. Remove four bolts attaching generator mounting bracket to cylinder head (6049), cylinder blocks (6010) and water pump, and remove generator mounting bracket. 13. Remove power steering pump pulley (3A733) from power steering pump (3A674). 14. Remove power steering lines from power steering pump. Remove four bolts attaching power steering pump to A/C compressor mounting bracket (2882) and remove power steering pump from A/C compressor mounting bracket. 15. Remove four bolts attaching A/C compressor (19703) to A/C compressor mounting bracket. Remove four bolts and one nut attaching A/C compressor mounting bracket to cylinder head and water pump. Remove A/C compressor mounting bracket from engine. 16. Remove the crankshaft pulley (6312) from the crankshaft vibration damper (6316). 17. Remove bolt and washer attaching crankshaft vibration damper. Remove crankshaft vibration damper using Crankshaft Damper Remover T58P-6316-D or Rotunda Gear and Pulley Puller 014-00293 or equivalent. Remove Woodruff key and crankshaft damper spacer from crankshaft (6303).