Thursday, March 15, 2012

How to replace Engine For 4.0L Engine On Ford Mustang?


The details to replace Engine For 2010 Ford Mustang 4.0L engine and other Mustang years is as follows:----

Removal & Installation



4.0L Engine
Specific to:
Ford Mustang 2009-2010

NOTE
Rotating the crankshaft pulley bolt counterclockwise could cause a reduction in clamp load on the crankshaft pulley and timing sprocket, which could cause severe engine damage.

All vehicles
  1. With the vehicle in NEUTRAL, position it on a hoist.
  2. Release the fuel system pressure.
  3. Disconnect the battery ground and positive cables.
  4. Remove the Air Cleaner (ACL) and ACL outlet pipe.
  5. Release the 2 windshield washer hose retainers and the one hood insulation pin-type retainer. 

    image
    Fig. Releasing the 2 windshield washer hose retainers and the hood pin type retainer
  6. Position the hood insulation aside and disconnect the windshield washer hose.
    NOTE
    Index-mark the hood hinge location to aid in hood installation.
  7. Remove the 4 bolts and the hood.
  8. Drain the cooling system.
Vehicles with automatic transmission
  1. Remove the transmission.
Vehicles with manual transmission
  1. Remove the clutch.
All vehicles
  1. Disconnect the 2 Heated Oxygen Sensor (HO2S) and the 2 Catalyst Monitor Sensor (CMS) electrical connectors.
  2. Remove the 4 catalytic converter-to-exhaust manifold nuts. Discard the nuts.
  3. Remove the oil pan drain plug and drain the engine oil. Install the drain plug and tighten to 19 ft. lbs. (26 Nm).
  4. Disconnect the upper radiator hose from the thermostat housing.
  5. Disconnect the lower radiator hose from the coolant pump.
  6. Remove the nut and Power Steering Pressure (PSP) tube bracket from the A/C compressor.

    Click image to see an enlarged view
    Fig. Removing the PSP nut and tube bracket from the A/C compressor
  7. Remove the bolt and detach the power steering supply hose bracket from the Front End Accessory Drive (FEAD) bracket.
  8. Disconnect the PSP switch electrical connector.
  9. Disconnect the A/C compressor and A/C high pressure switch electrical connectors.
  10. Detach the 2 wiring retainers from the FEAD bracket.
  11. Disconnect the fuel supply tube coupling.
  12. Loosen the 3 bolts on the power steering pump pulley.
  13. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
  14. Remove the 3 bolts and the power steering pump pulley.
  15. Remove the 3 bolts and position the power steering pump aside.
  16. Remove the 3 bolts, the nut and position the FEAD bracket and A/C compressor aside.
  17. Disconnect the 2 heater hoses from the coolant tube.
  18. Remove the 2 coolant tube bracket bolts.
    NOTE
    When removing the ignition wires, a slight twisting motion will break the seal and ease removal.
  19. Using the Spark Plug Wire Remover, disconnect the 6 spark plug wires from the spark plugs. Detach the retainers from the valve cover stud bolts and the ignition coil bracket.
  20. Detach the spark plug wire retainer from the intake manifold.
  21. Disconnect the radio ignition interference capacitor electrical connector.
  22. Remove the 2 upper ignition coil bracket bolts.
  23. Remove the 2 lower ignition coil bracket bolts and then remove the ignition coil and spark plug wires.
  24. Detach the crankcase vent tube from the LH valve cover and remove the tube.
  25. Disconnect the brake booster vacuum hose from the upper intake manifold.
  26. Disconnect the fuel vapor vent tube from the intake manifold.

    Click image to see an enlarged view
    Fig. Disconnecting the fuel vapor vent tube from the intake manifold
  27. Disconnect the upper and lower PCM electrical connectors.
  28. Disconnect the 16-pin electrical connector and detach the 2 wiring retainers.
  29. Detach the 3 wiring harness retainers.
  30. Remove the Power Distribution Box (PDB) cover.
  31. Remove the bolt and detach the B+ terminal from the PDB. Detach the pin-type retainer from the strut tower.
  32. Detach the PDB upper housing from the lower housing, loosen the bolt and then disconnect the 68-pin connector from the PDB.

    Click image to see an enlarged view
    Fig. Detaching the PDB upper housing from the lower housing
  33. Remove the bolt and detach the ground cable from the RH strut tower.
  34. Detach the battery cable harness pin-type retainer from the cowl.
  35. Install the Engine Lifting Bracket to the RH cylinder head.
  36. Install the Engine Lifting Bracket to the LH cylinder head.
  37. Remove the LH engine mount nut.
  38. Remove the RH engine mount nut.
  39. Using the Engine Lifting Bracket and Spreader Bar, remove the engine.
To install:

NOTE
Rotating the crankshaft pulley bolt counterclockwise could cause a reduction in clamp load on the crankshaft pulley and timing sprocket, which could cause severe engine damage.

All vehicles
  1. Using the Spreader Bar and Engine Lifting Bracket, position the engine in the vehicle.
  2. Install the RH engine mount nut. Tighten to 46 ft. lbs. (63 Nm).
  3. Install the LH engine mount nut. Tighten to 46 ft. lbs. (63 Nm).
  4. Attach the ground cable to the RH strut tower and install the bolt. Tighten to 89 inch lbs. (10 Nm).
  5. Attach the battery cable harness pin-type retainer to the cowl.
  6. Connect the 68-pin connector to the Power Distribution Box (PDB) and tighten the bolt. Tighten to 53 inch lbs. (6 Nm). Attach the PDB upper housing to the lower housing.
  7. Attach the B+ terminal to the PDB and install the bolt. Tighten to 106 inch lbs. (12 Nm). Attach the pin-type retainer from the strut tower.
  8. Install the PDB cover.
  9. Attach the 3 wiring harness retainers.
  10. Connect the 16-pin electrical connector and attach the 2 wiring retainers.
  11. Connect the upper and lower PCM electrical connectors.
  12. Connect the fuel vapor vent tube to the intake manifold.
  13. Connect the brake booster vacuum hose to the upper intake manifold.
  14. Attach the crankcase vent tube to the LH valve cover.
  15. Position the ignition coil and spark plug wires and install the 2 bolts. Tighten the M8 bolt to 18 ft. lbs. (24 Nm). Tighten the M12 bolt to 25 ft. lbs. (34 Nm).
  16. Install the 2 upper ignition coil bracket bolts. Tighten to 80 inch lbs. (9 Nm).
  17. Connect the ignition coil electrical connector.
  18. Connect the radio ignition interference capacitor electrical connector.
  19. Attach the spark plug wire retainer to the intake manifold.
    NOTE
    Apply a light film of silicone brake caliper grease and dielectric compound to the inside of the spark plug wire boots before installation.
  20. Connect the 6 spark plug wires to the spark plugs. Attach the retainers to the valve cover stud bolts and the ignition coil bracket.
  21. Install the 2 coolant tube bracket bolts. Tighten the M12 bolt to 25 ft. lbs. (34 Nm). Tighten the M8 bolt to 17 ft. lbs. (23 Nm).
  22. Connect the 2 heater hoses to the coolant tube.
  23. Position the Front End Accessory Drive (FEAD) bracket and A/C compressor. Install the 3 bolts and the nut. Tighten to 35 ft. lbs. (48 Nm).
  24. Position the power steering pump and install the 3 bolts. Tighten to 18 ft. lbs. (25 Nm).
  25. Position the power steering pump pulley and install the 3 bolts. Do not tighten at this time.
  26. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
  27. Tighten the 3 power steering pulley bolts. Tighten to 18 ft. lbs. (25 Nm).
  28. Connect the fuel supply tube coupling.
  29. Attach the 2 wiring retainers to the FEAD bracket.
  30. Connect the A/C compressor and A/C high pressure switch electrical connectors.
  31. Connect the Power Steering Pressure (PSP) switch electrical connector.
  32. Attach the power steering supply hose bracket to the FEAD bracket and install the bolt. Tighten to 97 inch lbs. (11 Nm).
  33. Position the Power Steering Pressure (PSP) tube bracket on the A/C compressor and install the nut. Tighten to 62 inch lbs. (7 Nm).
  34. Connect the lower radiator hose to the coolant pump.
  35. Connect the upper radiator hose to the thermostat housing.
  36. Position the ground strap and install the stud bolt. Tighten to 89 inch lbs. (10 Nm).
Vehicles with manual transmission
  1. Install the clutch.
Vehicles with automatic transmission
  1. Install the transmission.
All vehicles
  1. Install the 4 new catalytic converter-to-exhaust manifold nuts. Tighten to 33 ft. lbs. (45 Nm).
  2. Connect the 2 Heated Oxygen Sensor (HO2S) and the 2 Catalyst Monitor Sensor (CMS) electrical connectors.
    NOTE
    Use the index marks made during the removal procedure for correct hood alignment.
  3. Position the hood and install the 4 bolts. Tighten to 106 inch lbs. (12 Nm).
  4. Connect the windshield washer hose and position the hood insulation.
  5. Install the 1 hood insulation pin-type retainer and attach the 2 windshield washer hose retainers.
  6. Install the Air Cleaner (ACL) and ACL outlet pipe.
  7. Fill the engine with clean engine oil.
  8. Connect the battery ground and positive cables.
  9. Fill and bleed the cooling system.



These details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html



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