1999 ford ranger torque converter removal

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1989 Toyota 4Runner ENGINE PERFORMANCE Removal Overhaul And Installation

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Filed Under (Toyota Manuals) by admin on 26-10-2011

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CARBURETOR (COROLLA) REMOVAL 1) Drain cooling system. Disconnect air intake hose. Disconnect emission control hoses from air cleaner. Remove air cleaner mounting bolt and wing nut. Remove air cleaner. 2) Disconnect accelerator cable. Disconnect throttle cable (A/T). Disconnect carburetor wiring connector. Disconnect emission control hoses and tag for installation. Disconnect fuel inlet hose. Remove 4 carburetor mounting nuts and No. 1 vacuum pipe. Remove carburetor. DISASSEMBLY Air Horn 1) Remove air cleaner setting bolt. Remove fuel pipe clamp, union, fuel pipe and gaskets. Remove vacuum hoses. Remove pump and pivot screw and pump arm with connecting link. Disconnect choke link and choke opener link. 2 Remove 8 air horn screws and number plate, fuel pipe support and wire clamps. Remove air horn from carburetor body. Disconnect wiring from solenoid valves. 3) Remove float pivot pin, float and needle valve assembly. Remove air horn gasket, needle valve seat and gasket, power piston retainer, power piston and spring. Remove pump plunger and boot. See Fig. 2.
Fig. 1: Exploded View of Aisan Carburetor Main Body (Corolla) Courtesy of Toyota Motor Sales, U.S.A., Inc. Fig. 2: Exploded View of Air Horn Assembly (Corolla) Courtesy of Toyota Motor Sales, U.S.A., Inc. Main Body 1) Remove solenoid valves from carburetor body. Remove stopper gasket. Disconnect throttle positioner links and remove bracket attaching bolts. Remove accelerator pump retainer gasket and remove pump discharge weight, long spring and discharge large ball. See Fig. 1. 2) Remove pump dampening spring. Using tweezers, remove plunger retainer and check ball. Disconnect throttle positioner link and throttle position levers, washer and spring. Remove primary and secondary main passage plugs and gaskets. Remove primary and secondary main jets and gaskets. 3) Remove auxiliary acceleration pump (AAP) housing, spring and diaphragm. Remove AAP inlet plug and check ball. Remove outlet plug, short spring and small ball. Remove primary and secondary small venturies. 4) Remove sight glass retainer, sight glass and “O” ring. Remove throttle lever return spring and back spring. Remove throttle lever and fast idle cam. 5) Disconnect link and remove secondary throttle valve diaphragm assembly and gasket. Remove throttle position switch and bracket. Remove 3 body-to-flange screws and vacuum passage screw. Separate body from flange. See Fig. 3. Remove washer from throttle valve shaft. Remove idle mixture adjusting screw and idle speed adjusting screw.

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1998 Chevy Truck S10/ T10 Blazer 2WD Evaporator Core Service and Repair Manual

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Filed Under (Chevy Manuals) by admin on 14-05-2012

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Manual A/C REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the right side instrument panel sound insulator. 3. Remove the instrument panel storage compartment. 4. Disconnect the passenger side SIR. 5. Remove the lower right instrument panel mounting bolt. 6. Remove the left and right front speaker grilles. 7. Remove the center instrument panel sound insulator. 8. Remove the left side instrument panel sound insulator. 9. Disconnect the park brake release cable. 10. Remove the knee bolster. 11. Remove the lower left instrument panel mounting bolt. 12. Remove the BCM. 13. Disconnect the driver side SIR. 14. Remove the instrument panel cluster. 15. Remove the radio. 16. Remove the HVAC control assembly. 17. Remove the steering column retaining retaining nuts. 18. Lower the steering column. 19. Remove the instrument panel carrier. 20. Remove the left and right cowl vent grille panels. 21. Disconnect the underhood lamp electrical connector, if equipped. 22. Remove the hood. 23. Remove the VCM. 24. Remove the coolant recovery tank. 25. Remove the heater hoses. 26. Disconnect the electrical connectors from the grille mounted lamps. 27. Remove the right front headlamp assembly. 28. Remove the front bumper. 29. Remove the right wheelhouse panel. 30. Disconnect the radio antenna cable. 31. Disconnect the electrical connector for the horn. 32. Remove the right fender. 33. Remove the evaporator case heat shield, if equipped. 34. Remove the blower motor resistor. 35. Remove the evaporator case bolts and screws. 36. Remove the accumulator. 37. Remove the condenser to the evaporator line fitting. 38. Remove the bolts which retain the evaporator case to the bulkhead. 39. Pull back lightly on the heater case to remove the evaporator case. 40. Remove the evaporator case retaining screws. 41. Disassemble the evaporator case sections, and remove the evaporator core. NOTE: If replacing the evaporator core, remove the expansion (orofice) tube and install it into the new core. INSTALLATION PROCEDURE 1. Install the evaporator core. 2. Assemble the evaporator case sections. 3. Install the evaporator case retaining screws. Tighten to 2.5 N.m (24 in lb) . 4. Install the evaporator core assembly to the vehicle. 5. Install the bolts which retain the evaporator case to the bulkhead. Tighten the bolts to 4.5 N.m (40 lb in) . 6. Install the condenser to the evaporator line fitting. 7. Install the accumulator. 1998 Chevy Truck S10/T10 Blazer 2WD 8. Install the evaporator case bolts and screws. Tighten to 2.5 N.m (24 In in) . 9. Install the blower motor resistor. 10. Install the evaporator case heat shield, if equipped. 11. Install the right fender. 12. Connect the electrical connector for the horn. 13. Install the radio antenna cable. 14. Install the right wheelhouse panel. 15. Install the front bumper. 16. Install the right front headlamp assembly. 17. Connect the electrical connectors to the grille mounted lamps. 18. Install the heater hoses. 19. Install the coolant recovery tank. 20. Install the VCM. 21. Install the hood. 22. Connect the underhood lamp electrical connector, if equipped. 23. Install the left and right cowl vent grille panels. 24. Install the instrument panel carrier. 25. Reposition the the steering column, and install the steering column retaining nuts. 26. Install the HVAC control assembly. 27. Install the radio. 28. Install the instrument panel cluster. 29. Connect the driver side SIR. 30. Install the BCM. 31. Install the lower left instrument panel mounting bolt. 32. Install the knee bolster. 33. Connect the park brake release cable. 34. Install the left side instrument panel sound insulator. 35. Install the center instrument panel sound insulator. 36. Install the left and right front speaker grilles. 37. Install the lower right instrument panel mounting bolt. 38. Connect the passenger side SIR. 39. Install the instrument panel storage compartment. 40. Install the right side instrument panel sound insulator. 41. Connect the negative battery cable. 42. Inspect the system for leaks.

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TOYOTA AND LEXUS HIGHLANDER HYBRID REMOVAL AND INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 08-03-2012

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Engine and Vehicle Identification Chart………………………………………..4-2 General Engine Specifications………4-2 Engine Tune-Up Specifications……..4-2 Capacities ………………………………….4-3 Valve Specifications …………………….4-3 Crankshaft and Connecting Rod Specifications……………………..4-3 Camshaft and Bearing Specifications ……………………………4-4 Piston and Ring Specifications……..4-4 Torque Specifications………………….4-4 Wheel Alignment ………………………..4-5 Tire, Wheel and Ball Joint Specifications ……………………………4-5 Brake Specifications ……………………4-5 Scheduled Maintenance Intervals……………………………………4-6 STEERING AND SUSPENSION ………………4-28 A Air Bag…………………………………….4-28 Disarming ……………………………4-28 Precautions ………………………….4-28 Alternator …………………………………..4-7 B Brake Caliper ……………………………4-30 Removal And Installation……….4-30 C Camshaft and Valve Lifters…………4-14 Inspection ……………………………4-16 Removal & Installation…………..4-14 CV-Joints………………………………… 4-24 Overhaul ……………………………..4-24 Cylinder Head …………………………..4-10 Removal & Installation…………..4-10 D Disc Brake Pads………………………..4-32 Removal And Installation……….4-32 E Engine Assembly ………………………..4-7 Removal & Installation…………….4-7 Exhaust Manifold ………………………4-12 Removal & Installation…………..4-12 F Front Crankshaft Seal………………..4-14 Removal & Installation…………..4-14 Front Halfshaft………………………….4-23 Removal & Installation…………..4-23 Front Strut ……………………………….4-28 Removal & Installation…………..4-28 Front Wheel Bearing………………….4-29 Fuel Filter ………………………………..4-21 Fuel Injector……………………………..4-22 Removal & Installation…………..4-22 Fuel Pump ……………………………….4-21 Removal & Installation…………..4-21 Fuel System Pressure………………..4-21 Relieving ……………………………..4-21 H Heater Core………………………………..4-7 Removal & Installation…………….4-7 Hybrid Transaxle Assembly…………4-22 Removal & Installation…………..4-22 I Ignition Timing ………………………….. 4-7 Adjustment…………………………….4-7 Intake Manifold …………………………4-11 Removal & Installation…………..4-11 L Lower Ball Joint………………………..4-29 Removal & Installation…………..4-29 Lower Control Arm……………………4-29 Removal & Installation…………..4-29 O Oil Pan…………………………………….4-18 Removal & Installation…………..4-18 Oil Pump …………………………………4-18 Removal & Installation…………..4-18 P Pinion Seal ………………………………4-27 Removal & Installation…………..4-27 Piston and Ring………………………..4-21 Positioning ………………………….4-21 Power Rack And Pinion Steering Gear…………………………..4-28 Removal & Installation…………..4-28 R Rear Halfshaft………………………….. 4-24 Removal And Installation……….4-24 Rear Main Seal…………………………4-19 Removal & Installation…………..4-19 Rear Strut…………………………………4-28 Conventional Strut Overhaul…..4-28 Removal And Installation……….4-28 Rear Traction Motor…………………..4-22 Removal & Installation…………..4-22 Rear Wheel Bearing…………………..4-29 Removal And Installation……….4-29 T Timing Belt ………………………………4-19 Removal & Installation…………..4-19 V Valve Lash ……………………………….4-17 Adjustment…………………………..4-17 W Water Pump ……………………………..4-10 Removal & Installation………..

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1999 Ford Windstar Instrument Panel and Console REMOVAL AND INSTALLATION MANUAL

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Filed Under (Ford Manuals, Uncategorized) by admin on 23-04-2012

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Instrument Panel Removal CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. Remove the steering wheel. Refer to Section 211-04 . 2. Remove the passenger side air bag module. Refer to Section 501-20B . 3. Disconnect the antenna in-line connector. 4. Remove the RH instrument panel reinforcement bolt. 5. Close the glove compartment. 6. Remove the utility compartment. 1. Remove the four two part pin type retainers. 2. Remove the utility compartment. * Disconnect the power point electrical connector. 7. If equipped, disconnect the compact disc changer electrical connector. 8. Release the compact disc changer electrical connector locator. 9. Remove the LH and RH scuff plates. 10. Remove the LH and RH A-pillar lower trim panels. 11. Position the LH and RH front door weatherstrip seals aside. 12. Remove the RH ground bolts. 13. If equipped, remove LH and RH instrument panel lower insulators. 14. Remove the instrument panel lower steering column opening cover. 1. Remove the screws. 2. Remove the instrument panel lower steering column opening cover. 15. Remove the instrument panel opening cover reinforcement. 1. Remove the bolts. 2. Remove the instrument panel opening cover reinforcement. 16. Disconnect the LH wiring harness electrical connectors. 17. Disconnect the electronic crash sensor (ECS) electrical connector. 1. Release the locking clip. 2. Disconnect the ECS electrical connector 18. Disconnect the automatic transmission shift cable. 1. Disconnect the cable from the steering column shift tube lever. 2. Disconnect the cable from the steering column bracket. 19. Separate the intermediate shaft from the steering column. 1. Remove the pinch bolt. 2. Separate the intermediate shaft from the steering column. 20. Disconnect the climate control harness electrical connector. 21. Disconnect the climate control vacuum harness connector. 22. Disconnect the fuse junction panel electrical connectors. 23. Remove the LH instrument panel reinforcement bol 4. Remove the four instrument panel center support bolts. 25. Remove the instrument panel defroster opening grille. * If equipped, disconnect the sunload sensor electrical connector. 26. Remove the cowl top bolts. 27. Remove the RH cowl side bolts. 28. Remove the LH cowl side bolts. 29. NOTE: Two technicians are required to carry out this step. Remove the instrument panel. Installation CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. NOTE: Two technicians are required to carry out this step

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2002 Land Rover Freelander (LN) Camshaft Timing Belt Service Repair

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Filed Under (Land Rover Manuals) by admin on 09-01-2012

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Service Repair No – 12.65.18 Remove 1. Disconnect battery earth lead. 2. Remove ancillary drive belt . 3. Remove RH front road wheel. 4. Remove 3 bolts securing RH splash shield to body and remove shield. 5. Remove 3 bolts securing camshaft timing belt LH rear cover and remove cover. 6. Rotate crankshaft in a clockwise direction and align the engine “SAFE” position, notch on crankshaft pulley aligned to the “ARROW” on front mounting plate and the timing marks aligned on the rear camshaft gears as illustrated 7. Remove bolt securing PAS pipe to engine front mounting plate. 8. Remove 3 Torx screws securing PAS pump pulley and remove pulley. Zoom Sized for Print Zoom Sized for Print Zoom Sized for Print 9. Remove 3 bolts securing PAS pump to front mounting plate and tie pump aside. 10. Release alternator battery lead terminal cover, loosen terminal nut and disconnect lead from terminal. 11. Disconnect multiplug from alternator. 12. Remove lower bolt and upper nut and bolt securing alternator to front mounting plate. 13. Remove alternator. 14. Remove Torx screw securing idler pulley to front mounting plate and remove pulley 15. Loosen bolt securing lower engine steady to front subframe. 16. Remove bolt securing lower engine steady to sump mounting, release lower engine steady from sump mounting. 17. Remove 3 bolts securing camshaft timing belt RH front cover and remove cover 18. Remove 3 bolts securing camshaft timing belt LH front cover and remove cover. 19. Assemble LRT-12-161 to LRT-12-199 and secure with clamp bolt. 20. Insert LRT-12-161 with LRT-12-199 into crankshaft pulley, loosen and remove pulley bolt. 21. Remove special tool from crankshaft pulley and remove crankshaft pulley. 22. Remove 3 bolts securing camshaft timing belt lower cover to cylinder block and remove cover. 23. Remove 2 bolts securing ancillary drive belt tensioner and remove tensioner. 24. Note fitted position of heat shield on A/C compressor and remove 3 bolts securing A/C compressor to front mounting plate and cylinder block. Release A/C compressor and heat shield and position aside. 25. Drain engine oil.

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1996 Nissan Altima GLE TIMING CHAIN REMOVAL AND INSTALLATION MANUAL

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Filed Under (Nissan Manuals) by admin on 24-02-2011

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Removal 1. Release fuel pressure. See FUEL PRESSURE RELEASE . Drain coolant from radiator and cylinder block. Drain engine oil. Disconnect all necessary coolant hoses, electrical connectors, vacuum hoses, fuel lines and control cables. 2. Remove front exhaust tube. Remove intake manifold collector supports, and intake manifold. Remove exhaust manifold with catalytic converter. Remove air injection valve pipe. Remove intake air duct. Remove radiator fan and shroud. Remove injectors and fuel rail as an assembly. Remove distributor cap and spark plugs. 3. Set cylinder No. 1 at TDC of compression stroke, ensuring marks on crankshaft pulley and front cover align, and distributor rotor points to spark plug wire No. 1 on cap. Remove cylinder head cover. Remove distributor. 4. Prevent camshafts from turning, and remove camshaft sprocket bolts. Remove camshaft sprocket. See Fig. 13 . Mark and remove camshaft bearing caps in reverse order of installation. See Fig. 16 . Remove camshafts. 5. Loosen cylinder head bolts in 2 or 3 steps, in reverse order of tightening sequence. See Fig. 11 . Remove camshaft sprocket cover. Remove outer (upper) chain tensioner and guide. Remove outer timing chain. Remove idler sprocket bolt. Remove cylinder head. 6. Remove oil pan and oil strainer. See OIL PAN. Remove accessory drive belts. Remove A/C compressor idler pulley (if equipped). Remove crankshaft pulley. Remove front cover. Remove chain tensioner, tensioner arm and chain guides. Remove inner (lower) timing chain and idler sprocket. Remove oil pump drive spacer and crankshaft sprocket. Inspection 1. Inspect chain roller links. Replace chain if roller links are cracked or worn. Inspect cylinder head and cylinder block mating surfaces for warpage. If warpage exceeds specification, machine cylinder head. See CYLINDER HEAD under ENGINE SPECIFICATIONS. 2. If machining reduces cylinder head height to less than specification, replace cylinder head. After machining, rotate camshaft by hand. Replace cylinder head if camshaft does not rotate freely.

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2001 Toyota Echo Transmission and Drivetrain Removal And Installation Manual

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Filed Under (Toyota Manuals) by admin on 10-03-2012

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REMOVAL 1. REMOVE HOOD HINT: At the time of installation, please refer to the following item. Adjust the hood. 2. REMOVE WIPER ARM HINT: At the time of installation, please refer to the following item. Adjust the installation position of the wiper arms 3. REMOVE RH AND LH COWL TOP VENTILATOR LOUVERS 4. REMOVE NO. 2 CYLINDER HEAD COVER Remove the 4 nuts and No. 2 cylinder head cover. Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.) 5. REMOVE BATTERY AND AIR CLEANER CASE ASSEMBLY WITH AIR HOSE 6. DISCONNECT WIRE HARNESS FROM TRANSAXLE Remove the set bolt of the wire harness clamp. 7. DISCONNECT CONTROL CABLE a. Remove the 2 clips and washers. b. Remove the 2 clips and disconnect the control cables from the transaxle. 8. DISCONNECT CLUTCH RELEASE CYLINDER a. Remove the set bolt of the clutch line. Torque: 4.9 Nm (50 kgf-cm, 43 inch lbs.) b. Remove the 2 set bolts of the clutch release cylinder. Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.) 9. DISCONNECT GROUND CABLE Remove the set bolt of the ground cable from the engine left mounting bracket. 10. DISCONNECT BACK-UP LIGHT SWITCH AND VEHICLE SPEED SENSOR CONNECTORS 11. REMOVE 2 TRANSAXLE UPPER SIDE MOUNTING BOLTS Torque: 33 Nm (340 kgf-cm, 25 ft. lbs.) 12. REMOVE STARTER SET BOLT Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.) 13. ATTACH ENGINE SLING DEVICE TO ENGINE HANGER Zoom Sized for Print Zoom Sized for Print Zoom Sized for Print a. Remove the bolt. b. Install the 2 No. 1 engine hangers with the bolts in the correct direction. Parts No.: No. 1 engine hanger: 12281-21010 Bolt: 91642-81025 Torque: 40 Nm (400 kgf-cm, 29 ft. lbs.) c. Attach the engine chain hoist to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. 14. RAISE VEHICLE CAUTION: Make sure that the vehicle is securely supported. 15. REMOVE LH ENGINE UNDER COVER 16. DRAIN TRANSAXLE OIL Oil grade: API GL-4 or GL-5 Viscosity: SAE 75W-90 Capacity: 1.9 liters (2.0 US qts, 1.7 Imp. qts) Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.) 17. REMOVE RH AND LH FRONT DRIVE SHAFTS 18. REMOVE SUSPENSION MEMBER a. Remove the 2 set nuts and bolt of the engine rear mounting insulator from the suspension member. b. Disconnect the sliding yoke. c. Power steering: Disconnect the pressure feed and return tubes. d. Power steering: Disconnect the tube clamp

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1996 Toyota Supra A/T TRANSMISSION REMOVAL AND INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 16-03-2012

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Removal 1) Disconnect negative battery cable. Remove battery, battery tray, air cleaner assembly and air cleaner case. Disconnect throttle valve cable from throttle body. Remove cruise control actuator with mounting bracket from body. 2) Raise and support vehicle. Disconnect necessary electrical connectors and ground cables for transaxle removal. Disconnect shift cable and oil cooler lines at transaxle. Remove shift cable clamp bracket from transaxle. 3) Remove front (radiator side) engine mount shock absorber- to-lower frame assembly bolts. Remove front (radiator side) engine mount-to-lower frame assembly bolts/nuts. Remove starter. 4) Remove front (radiator side) exhaust manifold brace from rear of exhaust manifolds. Brace fits between rear of exhaust manifold and front of transaxle. 5) Remove 4 upper transaxle-to-cylinder block bolts. Support engine with hoist. Steering gear assembly must be supported in place during transaxle removal. Secure steering gear assembly to engine hoist using an attaching strap placed at each end of steering gear assembly. 6) Remove front wheels. Remove front exhaust pipe located between exhaust manifolds and rear exhaust pipe. Drain transaxle fluid. Remove axle shafts from transaxle. See appropriate AXLE SHAFTS article in AXLE SHAFTS & TRANSFER CASES section. 7) Disconnect shift control cable from mounting bracket. Remove rear (firewall side) engine mount-to-lower frame assembly bolts/nuts. Remove transaxle mount-to-transaxle bolts at driver’s side end of transaxle. 8) Remove stabilizer bar mount bracket-to-lower frame assembly bolts. Remove steering gear assembly-to-lower frame assembly bolts/nuts. Support lower frame assembly with floor jack. Lower frame assembly is located below engine and transaxle. 9) Disconnect power steering reservoir pipe mounting brackets from lower frame assembly. Remove bolts for each fender liner from lower frame assembly. Remove lower frame assembly mounting brackets. Lower frame assembly mounting brackets are located on front and rear of lower frame assembly and attach lower frame assembly to body. Remove lower frame assembly. 10) Support transaxle with transmission jack. Remove torque converter cover from front of transaxle. Remove torque converter bolts. Remove remaining exhaust manifold support brace. Remove remaining transaxle-to-cylinder block bolts. Lower transaxle from vehicle.

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2001 F-Super Duty 250-550/Excursion/F-53 Motorhome Chassis REMOVAL AND INSTALLATION MANUAL

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Filed Under (Ford Manuals) by admin on 18-02-2012

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Wheel Hub Removal All vehicles 1. Remove the wheel and tire assembly. For additional information, refer to Section 204-04 . 2. NOTE: Caliper is removed for clarity. Position aside the front disc brake caliper and anchor plate (2B292). 1. Remove the two front disc brake caliper anchor plate bolts. 2. Remove the front disc brake caliper anchor plate and position aside. 3. NOTE: Carry out this step for F-250 and F-350 4×4 SRW vehicles. Remove the rotor. 4. NOTE: Carry out this step for DRW vehicles. NOTE: If excessive force must be used during brake rotor removal, the brake rotors should be checked for lateral runout prior to installation. For additional information, refer to Section 206-00 . Remove the eight hub extender nuts, the hub plate and the rotor. 1. Remove the eight hub plate nuts. 2. Remove the hub plate. 3. Remove the rotor. 5. Remove the hub lock. 1. Remove the retainer ring. 2. Pull outward and remove the hub lock. 6. Remove the axle shaft thrust washers. 1. Remove the snap ring. 2. Remove the three thrust washers. Vehicles equipped with ABS 7. sensor from the bearing. Disconnect the ABS wheel sensor harness. 1. Disconnect the connector. 2. Disconnect the harness routing clips. All vehicles 8. NOTE: The wheel hub and bearing is a slip fit design and should not require a puller to remove it. Remove the wheel hub and bearing. 1. Remove the four lock nuts. 2. Remove the wheel hub and bearing 9. If necessary, remove the brake disc shield. Vehicles with ABS 10. If necessary, remove the bolt and the ABS sensor. All vehicles 11. NOTE: If necessary, position the hub in a soft-jawed vise. Install two nuts on the studs and use the inner nut to remove the studs. 12. Remove and discard the O-ring. Installation All vehicles 1. NOTE: Any time the wheel hub is removed for any reason, a new O-ring seal must be installed. Failure to do so can cause a vacuum leak and loss of four wheel drive operations. Install a new O-ring. 2. NOTE: Position the hub in a soft-jawed vise. Install two nuts on the studs and use the outer nut to install the studs. Vehicles equipped with ABS 3. Position the ABS sensor and install the bolt. All vehicles 4. Position the brake disc shield. 5. NOTE: Apply a coat of Ford High Temperature 4×4 Front Axle and Wheel Bearing Grease E8TZ-19590-A meeting Ford specification ESA-M1C198-A to the O-ring area of the wheel hub and bearing before installing the hub and bearing. Install the wheel hub and bearing. 1. Position the wheel hub and bearing. 2. Install the four lock nuts. Vehicle equipped with ABS 6. NOTE: The following step applies only to vehicles equipped with ABS. Connect the ABS sensor harness. 1. Position the ABS sensor harness and install the routing clips. 2. Connect the harness connector. All vehicles 7. n-metallic thrust washer must be installed between the two metal thrust washers. Failure to do so will cause severe wear to the non-metallic thrust washer, allowing the axle shaft to travel further in and out during torque thrust causing damage to the wheel hub and bearing, the axle shaft end seal and the axle shaft. Install the snap ring. 1. Position the three thrust washers onto the axle shaft. 2. Install the snap ring. 8. NOTE: Any time the hub lock is removed, a new O-ring seal must be installed. Failure to do so can cause a vacuum leak and loss of four wheel drive functions. Install a new O-ring. 9. Install the hub lock. 1. Position the hub lock. 2. Install the retainer ring. 10. Position the front disc brake rotor (1125) to the wheel hub (1104). Make sure the wheel hub and the front disc brake rotor braking and mounting surfaces are clean. ? Use brake parts cleaner to clean the front disc brake rotor. 11. NOTE: Carry out this step for DRW vehicles only. Install the front wheel hub extender and nuts.

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2002 Ford Explorer Sport/ Sport Trac Cylinder Head Removal and installation manual

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Filed Under (Ford Manuals) by admin on 02-06-2012

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Removal Both cylinder heads 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information , refer to Section 100-02 . 2. Relieve the fuel system pressure. For additional information, refer to Section 310-00 . 3. Drain the cooling system. For additional information, refer to Section 303-03 . 4. Remove the intake manifold. For additional information, refer to Intake Manifold in this section. 5. Remove the cooling fan shroud. For additional information, refer to Section 303-03 . 6. Remove the accessory drive belt. For additional information, refer to Section 303-05 7. Remove the LH valve cover. For additional information, refer to Valve Cover — LH in this section. 8. Remove the RH valve cover. For additional information, refer to Valve Cover — RH in this section. 9. Disconnect the generator electrical connections. 10. Remove the accessory drive belt tensioner. 11. Remove the bolts and the generator and generator mounting bracket as an assembly. 12. Disconnect the crankshaft position (CKP) sensor electrical connector. 13. Disconnect the wiring harness retainers. 14. Disconnect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors. 15. Disconnect the exhaust gas recirculation (EGR) tube fitting. 16. Remove the upper heater coolant hose. 1. Squeeze the heater hose clamp. 2. Remove the heater coolant hose. 17. Remove the lower heater coolant hose and position aside. 1. Remove the bolt. 2. Squeeze the hose clamp. 3. Remove the heater coolant hose and position aside. 18. NOTE: The coolant hose will be removed with the thermostat housing. Move the coolant bypass hose clamp off the water pump outlet. 19. Remove the bolts, the thermostat housing and the bypass hose. 20. Remove the bolt and detach the wiring harness retainer. 21. Remove the bolts and position the accessory drive bracket aside.22. Detach the wiring harness retainer. 23. Remove the bolt and the oil level indicator tube. 24. Using the special tool, disconnect the LH spark plug wires from the spark plugs. 25. Disconnect the fuel pulse damper vacuum connector. 26. Remove the four bolts and position the fuel supply tube aside. 27. Remove the bolts and the fuel rail and injectors as an assembly.28. NOTE: Mark each of the roller followers to make sure it is installed in its original position during reassembly. Use the special tool to remove the roller followers. 29. Remove the lower radiator hose. 30. Remove the nut and position the A/C tube bracket aside. 31. Using the special tool, set the No. 1 piston at top dead center (TDC). RH cylinder head 32. Remove the RH fenderwell splash shield. 33. Remove the RH camshaft chain tensioner.

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