REMOVAL & INSTALLATION
CAUTION:When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.
NOTE:For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Place mating marks on engine hood and other major assemblies before removal.
FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS
WARNING:Fuel system is under pressure. Release pressure before servicing fuel system components.
Remove fuel cap to release fuel tank pressure. Connect EFI Pressure Gauge (T80L-9974-B) to relief valve on right rear corner of fuel rail. Release pressure using valve on pressure gauge.
Before disconnecting fuel lines, disconnect negative battery cable. To disconnect fuel lines, remove retaining clip from outside of fuel line coupling.
Install Spring Lock Coupling Remover (D87L-9280-A) for 3/8" line or (D87L-9280-B) for 1/2" line on fuel line coupling so it enters cage opening. See Fig. 1.
Push spring lock coupling remover into cage opening to release female fitting from garter spring. Pull couplings apart. Remove spring lock coupling remover.
When installing fuel lines, fit NEW fuel resistant "O" rings (Brown) on fuel lines. Before installing, lightly coat "O" rings with clean engine oil. Clean fittings, and replace garter spring (if necessary).
Install female fitting to male fitting and push until garter spring snaps over flared end of female fitting. Ensure lines lock together and garter spring is over female fitting flared end.
Install retaining clip. Install Black retaining clip on fuel supply line and Gray clip on fuel return line. Ensure horseshoe portion of clip is over coupling. DO NOT install retaining clip over rubber fuel line.
Fig. 1: Disconnecting Fuel Lines
Courtesy of FORD MOTOR CO.
Removal (Expedition, Navigator & F150/250 Pickup)
WARNING:Ensure air suspension system is shut off prior to hoisting, jacking or towing an air suspension vehicle. Air suspension switch is located behind right kick panel. Failure to do so can result in inflation or deflation of air springs, which may cause vehicle to shift during servicing.
Disconnect negative battery cable. Remove hood. Drain cooling system. Remove radiator. Discharge A/C system using approved refrigerant recovery/recycling equipment. Release fuel pressure and disconnect fuel lines. See FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS.
On Expedition and Navigator, remove air conditioning condenser and EGR manifold tube. Unclip mega fuse holders from junction block bracket. Disconnect starter relay cables.
On all models, remove upper intake manifold. See INTAKE MANIFOLD. Remove bulkhead connector cover. Disconnect necessary grounds and harness connectors. Disconnect necessary water and vacuum connections. Unbolt power steering bracket, and position reservoir and bracket assembly aside. Remove ignition coils and brackets.
Raise and support vehicle. Remove starter. Remove A/C compressor. Remove transmission cooler line from block mounted clip. Remove transmission inspection cover, torque converter bolts and transmission-to engine bolts. Remove power steering retaining bolts and position power steering pump aside.
Disconnect dual-converter "Y" pipe from exhaust manifolds, and position aside. Remove right and left engine mount bolts. Lower vehicle and support transmission. Remove engine from vehicle.
Friday, November 28th, 2008 AT 7:11 PM