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2006 Ford Pickup F350 Super Duty Intake Manifold Component Removal And Installation Manual

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Filed Under (Ford Manuals) by admin on 13-05-2011

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Removal All vehicles 1. Remove the auxiliary battery. For additional information, refer to BATTERY, MOUNTING AND CABLES . 2. Remove the cooling fan stator. For additional information, refer to ENGINE COOLING . 3. Remove the degas bottle. For additional information, refer to ENGINE COOLING . 4. Disconnect the upper radiator hose. Fig. 23: Locating Upper Radiator Hose Courtesy of FORD MOTOR CO. Fig. 24: Locating Turbocharger-To-CAC Duct Courtesy of FORD MOTOR CO. 5. Remove the turbocharger-to-CAC duct Vehicles with dual generators 6. Remove the accessory drive belt. Fig. 25: Rotating Drive Belt Tensioner Clockwise Courtesy of FORD MOTOR CO. 7. Remove the bolt and the accessory drive belt tensioner. Fig. 26: Locating Accessory Drive Belt Tensioner Bolt Courtesy of FORD MOTOR CO. 8. Remove the accessory drive belt. Fig. 27: Rotating Accessory Drive Belt Tensioner Courtesy of FORD MOTOR CO. 9. Remove the bolts, bracket and accessory drive belt idler pulley. Fig. 28: Locating Bracket And Accessory Drive Belt Idler Pulley Bolts Courtesy of FORD MOTOR CO. 10. Remove the bolts and the accessory drive belt tensioner. Fig. 29: Locating Accessory Drive Belt Tensioner Bolts Courtesy of FORD MOTOR CO. 11. Disconnect the wiring harness retainer, generator electrical connector and B+ wire. Fig. 30: Locating Wire Retainer And Generator Electrical Connectors Courtesy of FORD MOTOR CO. 12. Remove the bolts and the generator with mounting bracket.

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2004-2008 FORD F150 FRONT LEVELING SYSTEM INSTALLATION MANUAL

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Filed Under (Ford Manuals) by admin on 19-12-2011

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Front End Installation: 1. To begin installation, block the rear tires of the vehicle so that the vehicle is stable and can’t roll backwards. Safely lift the front of the vehicle and support the frame with jack stands. Place jack stands on both the driver and the p sides of the vehicle. Next remove the wheel from both sides. assenger s 2. Remove the upper strut mounts with a 15-mm wrench or . m socket. Using a ball cket. Use an socket. You will need a socket to remove the far strut mount 3. Remove the sway bar lower link pin bolt from the bottom of the control arm with an 18 mm socket. 4. Disconnect the tie rod end with a 21 m peen hammer or impact tool, hit the steering knuckle (not the tie rod) until the tie rod pops out. If you use a tie rod pickle fork, be careful not to cut the tie rod boot. A severed tie rod boot will allow dirt and moisture to damage the tie rod end. 5. Remove the upper ball joint nut with a 21 mm so impact tool or ball peen hammer and hit the steering knuckle until the upper control arm pops out.
6. Support the knuckle with a bungee cord or safety wire so not to overextend the CV axel or stretch the brake hydraulic hose. 7. Next remove the struts lower bolt. Using a 27 mm wrench, hold the nut and remove the bolt with a 30 mm socket. 8. Remove the strut assembly. 9. Place the strut extension on the top of the strut, hold the part up to start the nuts onto the factory studs. ** Caution: Use the factory nuts with the factory studs** 10. Run down nuts snug with end wrench. Torque to OEM specs. 11. Place strut back into upper strut mount. Tighten provided nuts snug with wrench or ratchet (after install, you will torque to OEM specs). 12. Use a pry bar to position the lower control arm and the strut mount to reinstall the mounting bolt. Torque to OEM specs. 13. Place a jack under the lower control arm. Raise the lower control arm to reattach the ball joint. A pry bar may be used to hold the upper control arm into position. Torque the ball joint nut to OEM specs. 14. Reattach the tie rod end. Torque to OEM specs. 15. Reattach the sway bar. Torque to OEM specs. 16. Reattach the wheel. Torque to OEM specs. 17. Repeat on opposite side. 18. Lower vehicle to ground and torque strut mounts to OEM specs. 19. Align the vehicle. A certified alignment technician that is experienced with lifted vehicles is recommended to perform the alignment

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1985 -1995 5.0L Ford V8s with Hydraulic Roller Lifter Cams ACCU-DRIVE CAM GEAR DRIVE SYSTEM Installation Manual

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Filed Under (Ford Manuals) by admin on 03-01-2012

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1. Remove stock timing cover. Rotate engine to Top Dead Center of cylinder #1 so that the timing marks on the original crank and cam sprockets are directly lined up with each other, i.e. the mark on the crank sprocket will be straight up and the mark on the cam sprocket will be straight down. Using suitable gear puller, remove stock crank and camshaft sprockets and timing chain. Refer to repair manual if necessary for individual steps. 2. Assemble Accu-Drive as shown in Figure 1. 3. Install crank gear with the large inside chamfer toward rear of engine and timing mark toward front of engine. Make certain crankshaft drive key is aligned with keyway of the crank gear before assembling. 4. See Figure 2 “Camshaft Gear Assembly”for correct assembly. (a) Place well-lubricated thrust washer on the rear (block) side of cam gear. (b) The Edelbrock Accu-Drive system is furnished with an 0.032″ thick thrust ring that installs between the back side of the cam gear and the front side of the camshaft thrust plate. Torque the thrust plate retaining capscrews to 9-12 ft./lbs. NOTE: No thrust button is used on Ford engines. (c) Select the desired keyway in the crank gear “0″ (standard), “A” (4ºadvanced at the crank, 2º at the cam), or “R” Place a small amount of clay on the front end of both axles as shown in Figure 3. NOTE: It will be necessary to cut material off rib inside front cover to hold idler gears in place. (b) Install front cover with gasket in place. (c) Remove cover and measure the thickness of the compressed clay. It should be .005″-.030″. Do not tighten cover down until proper clearance has been obtained. Without sufficient clearance, there is risk of cracking the cover when tightened down. (d) If clearance is less than .005, you will need to grind off idler axle as shown to obtain proper clearance. If clearance is greater than .090, replace left side (larger idler side) stud with tapered end axle provided in the kit. Re-install idler assembly and recheck for minimum clearance between block and front cover. 8. With all gears correctly in mesh and timed, tighten the camshaft capscrew to 35 ft./lbs. It would also be a good idea to use Locktite™ or equivalent on the bolt threads prior to final assembly. 9. Lubricate all gears and bearings with engine oil. 10. Re-install the front cover. 11. Re-install all components removed in preparation for step 1

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1986 Ford Truck F 150 2WD Pickup Emission Maintenance Warning Module-Service Manual

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Filed Under (Ford Manuals) by admin on 23-06-2012

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EMISSION MAINTENANCE WARNING MODULE SERVICE INFORMATION ^LAMP – “EMISSIONS/CHECK ENGINE” – EMISSION MAINTENANCE WARNING MODULE – SERVICE INFORMATION LIGHT TRUCK: 1985-89 BRONCO 1985-87 BRONCO II 1985-89 ECONOLINE, F- 150, F-250, F-350 1985-88 RANGER 1986-87 AEROSTAR ISSUE: The Emission Maintenance Warning “EMW” module operates a light that is located on the instrument panel. For 1985-87 model year vehicles, the light will display the word “EMISSIONS”. For 1988-89 model year vehicles, the light will display the words “CHECK ENGINE”. When the light is lit, it is indicating that the 60,000 mile emission maintenance should be performed. After the maintenance is performed the EMW module must be reset to zero time. Another type of module is the “IMS” module. This module is not part of the light circuit and does not require maintenance. At a predetermined time, the IMS module directs the EEC IV processor to make a strategy change. A third type of module is the “COMBO” module. This module combines the functions of the IMS and the EMW modules. ACTION: Refer to the following module application charts for the specific vehicle application and location of the different types of modules. NOTE: FOR APPLICATIONS NOT LOSTED IN THE FOLLOWING MODULE APPLICATION CHARTS, THE “CHECK ENGINE” LIGHT IS CONTROLLED BY THE EEC IV PROCESSOR. THESE VEHICLES DO NOT USE THE “EMW” MODULE

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1999-2006 TOYOTA TUNDRA FRONT LEVELING SYSTEM FOR THE 6-LUG SUSPENSION INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 04-12-2011

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1. To begin installation, block the rear tires of the vehicle so that the vehicle is stable and can’t roll backwards. Safely lift the front of the vehicle and support the frame with jack stands. Place jack stands on both the driver and the passenger sides of the vehicle. Next remove the wheels from both sides. 2. Using a 17mm socket, remove the lower sway bar link bolt from both sides. HINT: If the stud turns together with the nut use a hex wrench or vice grips to hold the stud . 4. Next remove the strut’s lower mounting bolt with a 19 mm socket and wrench. NOTE: Once the nut is removed, it may be necessary to use a punch and hammer to free the bolt. 5. Remove the nuts from the three upper strut mounting bolts with a 14 mm ratchet. Be sure to support the strut assembly as the nuts are removed to prevent it from falling. 6. Remove the strut assembly from the vehicle and mount it in a bench vise. Install the steel strut extension on the top of the strut assembly. ** Caution: Use the factory nuts with the factory studs** 7. Run down nuts snug with end wrench. Torque to OEM specs. NOTE: Because of the shape of the steel spacer the strut will be rotated 180° when reinstalled. 8. Place strut back into upper strut mount. Tighten provided nuts snug with a 14mm wrench or ratchet (after install, you will torque to OEM specs). 9. Use a pry bar to position the lower control arm and the strut mount, and then reinstall the mounting bolt. Torque to OEM specs. 10. Place a jack under the lower control arm. Raise the lower control arm to reattach the lower ball joint bolts. Torque the ball joint nuts to OEM specs. 11. Repeat Steps 3 through 10 on the opposite side of the vehicle. 12. Reattach the sway bar link assembly on both sides of the vehicle. Torque to OEM specs. For 2wd trucks skip Step 13. 13. For 4×4 models only it is necessary to lower the differential using the provided spacers and bolts. Install the spacers following the instructions provided with the spacers. 14. Reattach the wheels. Torque to OEM specs. 15. Lower vehicle to the ground and torque strut mounts to OEM specs. 16. Align the vehicle. A certified alignment technician that is experienced with lifted vehicles is recommended to perform the alignment

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1994-2003 Ford F-Series Power Stroke 7.3L Edge Evolution Programmer Installation Manual

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Filed Under (Ford Manuals) by admin on 25-05-2012

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Connecting the Evolution 1. Turn the ignition switch to the OFF position. Locate the diagnostic connector under the dash near the steering column or under the glove compartment and connect the Evolution cable to this connector. After making the connection, the screen will first display the Edge Products logo and then the main startup displays: The numbers in the upper left portion of the screen represent the version number of the Evolution programmer. The character in the upper right portion of the screen represents the current programmed state of your vehicle. The following letters may appear: I – Programming was interrupted. (See Programming Interrupted section for more information) 1 – Vehicle has been programmed to L1 – TOW. 2 – Vehicle has been programmed to L2 – RACE. 3 – Vehicle has been programmed to L3 – EXTREME. Evolution FORD Power Stroke 7.3 Liter 11 2. Select your desired option by pressing the up or down keys on the left side of the programmer and press . Continue to the next section. Evolution FORD Power Stroke 7.3 Liter 12 Power Programming “Caution: Vehicle manufacturers do not recommend vehicle programming in extreme temperature. Please see the service manual of your vehicle to ensure that programming is being done in accordance to the original equipment manufacturers specifications.” If you selected Diagnostics from the Main Menu, go to that section in this instruction manual and follow the steps. If you selected Performance from the Main Menu, go to that section in this instruction manual and follow the steps. If you selected Power Programming, the screen displays the following message: 1. After turning the key ON (do not start the engine) and pressing , the screen displays the following message: Evolution FORD Power Stroke 7.3 Liter 13 Evolution FORD Power Stroke 7.3 Liter 14 2. The Evolution will check the PCM and determine if it is in the Master Calibration list. If the calibration is available, you will see the following message: Otherwise you will see the following message (See Update Required for more information): 3. You will then be instructed to turn the key OFF, Press and turn the key back to ON (do not start) to begin saving STOCK: Evolution FORD Power Stroke 7.3 Liter 15 During the storing process, you will see the following display:
Evolution FORD Power Stroke 7.3 Liter 16 4. If this is the first time the unit is used on a particular vehicle, the Evolution will build and verify the modified calibrations (Skip to step 5 for subsequent programming operations). During this process, you will see the following displays

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K40016 ADD-A-LEAF SPRING KIT INSTALLATION INSTRUCTIONS

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Filed Under (More Manuals) by admin on 19-04-2012

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CHEVY 1982-98 S Series all 2WD/4WD 1972-82 LUV PU 2 WD DODGE 1994-99 Ram 1500 2WD 1994-00 Ram 1500 4WD FORD 1990-96 F 150 std or ext cab 2WD 1982-89 F 150 std or ext cab 2WD 1983-1996 Ford Bronco II 4WD 1983-1996 Ford Bronco II 2WD 1983-1997 Ford Ranger 2WD/4WD 1990-00 Ford Ranger 2WD 1983-97 Ford Explorer 2WD/4WD 1972-84 Ford Courier 2WD K40016 ADD-A-LEAF SPRING KIT JEEP 1984-01 Jeep Cherokee 1974-86 CJ-5/CJ-7/CJ-8 4WD 1967-73 Jeepster/C101/C101 w multileaf Jeep Wrangler 1987-96 Front and Rear LAND ROVER 1959-1981 All 4wd MITSUBISHI 1986-91 Montero 1982-84 PU 2WD/4WD NISSAN 1968-1997 PU/Pathfinder 2WD/4WD TOYOTA 1963-98 Toyota PU/4 Runner with 2.5″ rear springs The K40016 Add-A-Leaf Spring Kit retrofits onto the following vehicles: The kit consists of two each 28″ Leaf Springs and two sets of two each longer bolts and nuts of different diameters. The same diameter bolt currently on the vehicle should be used and the other set discarded. • PLEASE READ ALL INSTRUCTIONS COMPLETELY BEFORE BEGINNING THE INSTALLATION • You must use 2-large “C-clamps” or a large vise to contain the elastic potential energy stored in a leaf spring when the center bolt is removed. • The new leaf spring will be placed in the existing spring assembly in a progressive pyramid shape. Example – if your number 1 Spring is 32″ long and the next one is 25″ long, the new Add-A-Leaf Spring should be place between them. • Some vehicles will have a flat helper stack. SEE ILLUSTRATION – DO NOT INSTALL THE NEW ADD-A-LEAF SPRING IN OR BELOW THE HELPER SPRIN(S). Helper spring assembly. Do not install Add-A-Leaf in or below this assembly Lowest allowable position for Add-A-Leaf

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2008 Ford F-250/350/450 6.4L Powerstroke diesel aft-filter system Installation Manual

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Filed Under (Ford Manuals) by admin on 08-12-2011

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Installation instructions: 1.) Raise and support vehicle. 2.) Lubricate all factory rubber hangers and pipe slip-connectors with penetrating oil. 3.) Loosen clamp, attaching inlet of stock muffler to inlet pipe. 4.) Remove muffler/tailpipe assembly from inlet pipe and rubber hangers; remove from vehicle. Removal of muffler/tailpipe can be made easier by first cutting the tailpipe from the muffler with a reciprocating saw. 5.) Remove hanger rod on inlet pipe from rubber frame hanger. 6.) Loosen clamp attaching inlet pipe to outlet of converter and remove pipe from vehicle. 7.) Place supplied 3.5? clamp with hole over small end of supplied adapter and install onto outlet of converter. Engage slot in adapter with index bump on converter outlet and place hole in clamp over bump. Tighten clamp fully. 8.) Place one supplied 4? clamp over inlet pipe slip-connector and install pipe onto adapter. Insert hanger rod on pipe into corresponding rubber hanger on frame. 9.) Rotate inlet pipe as needed to orient end of hanger rod, which is inserted into rubber hanger, in a horizontal position and tighten clamp at slip-connector fully 10.) Place one supplied 4? clamp over muffler inlet and install muffler onto inlet pipe. 11.) Place one supplied 4? clamp over inlet of tailpipe section “A” and install pipe onto muffler and into corresponding factory rubber hangers just above muffler. 12.) Place one supplied 4? clamp over inlet of tailpipe section “B” and install pipe into rear-most rubber frame hanger and onto outlet of tailpipe section “A”. 13.) Place remaining 4? clamp over tip inlet and install tip onto outlet of tailpipe section “B”. 14.) Align all components for desired fit and tighten all clamps fully

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2006 Ford F-SUPER DUTY Class A Motorhome Chassis INCOMPLETE VEHICLE MANUAL

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Filed Under (Ford Manuals) by admin on 26-05-2012

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Certain exhaust system components, including exhaust heat shielding systems, have been installed on some vehicles in our assembly plants in an effort to provide protection against engine compartment and exhaust system temperatures. Subsequent aftermarket installers/manufacturers are responsible for providing thermal protection (e.g. underbody heat shields) for any structure and/or equipment added to the vehicle and should not remove any components or exhaust heat shielding installed on the vehicle by Ford Motor Company. All exposed interior sheet metal of closed structures (e.g. fl oor pan of cab and/or secondary structure, tool boxes, etc.) should be covered with an insulating material capable of protecting vehicle occupants and contents from temperatures potentially up to 700°F. OZONE DEPLETING SUBSTANCE (ODS) OZONE DEPLETING SUBSTANCE (ODS) The Clean Air Act of 1990, Section 611 requires any product (i.e., completed vehicle) containing or manufactured with any Class I Ozone Depleting Substance on, or after May 15,1993 must be identifi ed with a “clearly and conspicuously attached label.” Ford Motor Company has eliminated Class I ODS from its manufacturing processes. All 2006 Ford Truck incomplete vehicles will not have Class I ODS content. Manufacturers, including subsequent stage manufacturers, are required to label their products if the product, including any component (whether manufactured by that manufacturer or not), contains a Class I ODS or if the manufacturer used a Class I ODS in the manufacturing of the product. In the case where Ford Motor Company provides a label saying the incomplete vehicle contains a Class I ODS that information must be placed on the product warning label. (See EPA regulation on wording, placement, size, and combining labels.) In Canada consult the appropriate Provincial or Territorial Ministry of Environment. EMISSION CONTROL INFORMATION LABEL To meet United States Environmental Protection Agency regulations, the Important Vehicle Information (tune-up and fuel tank capacity) labels must be affi xed in a location that is readily visible after installation and in such a manner that it cannot be removed without destroying or defacing the label. The label shall not be affi xed to any equipment that is easily detached from the vehicle. When emission control labels are supplied but not attached to the vehicle (i.e., tune-up label or fuel tank label), they must be permanently mounted in a readily visible location to meet the preceding requirements. In addition, whether the label is already affi xed or to be affi xed, no components shall be installed which visibly obscure the label in any way that fails to satisfy the visibility requirements described in the California Emission Control Label Specifications. For Canadian requirements consult Section 1100 8 (1) (d) (i), (ii), & (iii). CALIFORNIA FUEL VAPOR RECOVERY California regulations require that the vehicle fuel systems be designed to accommodate a vapor recovery fueling nozzle including unobstructed access to the fi ll pipe. Fuel fi ller pipes installed per the Figure B on page 15 will comply with the “Specifi cations For Fill Pipes and Openings of Motor Vehicle Fuel Tanks” referenced in Title 13 California Administrative Code provided no part of the aftermarket body, as installed, intrudes within a 254mm [10 in] radius cylinder which has its axis parallel to the ground at point “Z” and extends outward from the Ford Motor Company supplied fuel pipe housing component. The fuel pipe housing component is shown on the referenced fi gures and is attached to the aftermarket body via 4.76 mm [.188 in.] diameter rivets. Fuel fi ller pipes installed using the alternative bracket shown in Figure B, will comply with the above California vapor recovery regulations provided the aftermarket body does not interfere with the access zone as defi ned by the California Air Resources Board, and the areas adjacent to this opening cannot foreseeably damage the nozzle bellows or face plate of nozzles during insertion, latching, disposing or removal

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MULTI-BATTERY ISOLATOR APPLICATION INSTALLATION MANUAL

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Filed Under (More Manuals) by admin on 23-03-2012

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PLEASE READ INSTRUCTIONS COMPLETELY PRIOR TO STARTING INSTALLATION 4 3 2 1 GROUP GROUP GROUP GROUP General Motors (Delcotron/Delphi) Except Delcotron/Delphi CS series alternators (CS series used on most 1985 and newer GM vehicles). Ford Up to 1998 Chrysler All models, all years including Nippondenso externally regulated alternators. Jeep Equipped with Nippondenso externally regulated alternators Japanese Imports With alternators using external voltage regulator or external sensing. Motorola Load Handler Series or 8EM Remote Sense Series General Motors (Delcotron/Delphi) Equipped with Delcotron/Delphi CS series (most 1985 – 1993) or CS130-D series alternators (most 1993 and newer***) Jeep Vehicles equipped with Delcotron/Delphi CS series alternator (most 1985-1990). Toyota, Honda & Some Imports 1985 and newer equipped with Nippondenso alternator with internal regulators or alternators with an “S” (sense) terminal. Motorola Other than Load Handler Series Bosch Requiring regulator sensing A Group 3 Isolator will have a colored fourth terminal indicating the “R” terminal. Unplugging the plug-in connector from the alternator and counting the number of holes in the connector can identify the CS series alternator. The CS series will have three small and one large hole. The CS130-D alternator has four pin terminals all the same size. The SI series will have two slotted holes in the connector. ***Delco/Delphi CS series alternators require a separate sense wire which is included with the connector kit. The connector kit may or may not be included with the Isolator, but is available as an accessory. All Group 2 Isolators may be used in Group 1 applications. Simply disregard the additional excitation (“E”) terminal. A Group 2 Isolator will have a colored fourth terminal indicating the “E” terminal. Battery Isolators are not compatible with these alternators. A Battery Separator is recommended for these applications. Alternators with internal voltage sensing, e. g. some Mitsubishi and Hitachi , or single wire self exciting Delco/Delphi alternators. Isolators may be used if the alternator is modified. For further information on Group 4 Isolation Technolgy contact Sure Power Industries.

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