Thursday, March 15, 2012

How to replace Engine For 5.4L 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:--


5.4L Engine
Specific to:
Ford Mustang 2009-2010

WARNING
Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.


WARNING
Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

  1. With the vehicle in NEUTRAL, position it on a hoist.
  2. Release the 2 windshield washer hose retainers and the one hood insulation pin-type retainer.
  3. Position the hood insulation aside and disconnect the windshield washer hose.
    NOTE
    Index-mark the hood hinge location to aid in hood installation.
  4. Remove the 4 bolts and the hood.
  5. Release the fuel system pressure.
  6. If equipped, remove the 4 nuts and the strut tower cross brace. 

    image
    Fig. Removing the strut tower cross brace
  7. Remove the battery and tray.
  8. Remove the Air Cleaner (ACL) and ACL outlet pipe.
  9. Remove the 2 steering column dash boot nuts.
  10. Drain the cooling system.
  11. Drain the Supercharger (SC) cooling system.
  12. Remove the engine coolant degas bottle.
  13. Remove the SC coolant degas bottle.
  14. Disconnect the upper radiator hose from the thermostat housing.
  15. Disconnect the cooling fan electrical connector.
  16. Remove the 2 bolts and the cooling fan assembly.
  17. Disconnect the coolant hose from the Charge Air Cooler (CAC).
  18. Disconnect the coolant hose from the coolant tube assembly (above the generator).
  19. Disconnect the coolant hose from the thermostat housing.
  20. Disconnect the coolant hose from the coolant pump.
  21. Disconnect the fuel supply tube.

    Click image to see an enlarged view
    Fig. Disconnecting the fuel supply tube
  22. Disconnect the Evaporative Emission (EVAP) tube and brake booster vacuum supply tube from the Throttle Body (TB) spacer.
  23. Disconnect the lower EVAP tube and electrical connector from the EVAP canister purge valve. Remove the EVAP canister purge valve.

    Click image to see an enlarged view
    Fig. Disconnecting the EVAP tube and brake booster vacuum supply tube from the TB spacer
  24. Disconnect the 2 heater hoses from the coolant tube assembly at the rear of the engine.

    Click image to see an enlarged view
    Fig. Disconnecting the 2 heater hoses from the coolant tube assembly at the rear of the engine
  25. Detach the pin-type wire harness retainer from the cowl.
  26. Detach the pin-type wiring harness retainer.
  27. Remove the Power Distribution Box (PDB) cover.
  28. 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 and disconnecting the 68 pin connector from the PDB
  29. Disconnect the jumper harness electrical connector.
  30. Disconnect the upper and lower PCM electrical connectors.

    Click image to see an enlarged view
    Fig. Disconnecting the upper and lower PCM electrical connectors
  31. Disconnect the 16-pin electrical connector and detach the 2 wiring retainers.
  32. Disconnect the hose from the power steering reservoir. Drain the power steering fluid into a suitable container.
  33. Disconnect the A/C pressure transducer electrical connector.
  34. Rotate the SC drive belt tensioner clockwise and remove the drive belt from the SC drive pulley.

    Click image to see an enlarged view
    Fig. Rotating the SC drive belt tensioner and removing the drive belt from the SC drive pulley
  35. Disconnect the coolant hose from the oil cooler.
  36. Disconnect the lower radiator hose from the radiator. Remove the lower radiator hose assembly from the vehicle.
  37. Disconnect the Power Steering Pressure (PSP) tube fitting. Discard the Teflon® seal.

    Click image to see an enlarged view
    Fig. Disconnecting the PSP tube fitting
  38. Disconnect the power steering return hose.
  39. Remove the nut and disconnect the B+ wire from the generator.
  40. Detach the wiring harness retainer from the oil pan stud bolt.
  41. Remove the nut and wire harness bracket from the oil pan stud bolt.

    Click image to see an enlarged view
    Fig. Removing the nut and wire harness bracket from the oil pan stud bolt
  42. Disconnect the Crankshaft Position (CKP) sensor electrical connector.

    Click image to see an enlarged view
    Fig. Disconnecting the CKP sensor electrical connector
  43. Detach the wire harness retainer from the A/C compressor stud bolt.
  44. Disconnect the A/C compressor electrical connector.

    Click image to see an enlarged view
    Fig. Disconnecting the A/C compressor electrical connector
  45. Detach the wiring harness pin-type retainer from the back of the A/C compressor.

    Click image to see an enlarged view
    Fig. Detaching the wiring harness pin type retainer from the back of the A/C compressor
  46. Position the SC drive belt away from the A/C compressor and detach the 2 wiring harness retainers from the A/C compressor stud bolts.

    Click image to see an enlarged view
    Fig. Detaching the 2 wiring harness retainers from the A/C compressor stud bolts
  47. Remove the 3 stud bolts and position the A/C compressor aside.
  48. Remove the nut and the ground wire from the RH engine support insulator bracket stud bolt.
  49. Detach the 2 wiring harness pin-type retainers from the oil pan.

    Click image to see an enlarged view
    Fig. Removing the 2 wiring harness pin type retainers from the oil pan
  50. Remove the starter solenoid terminal cover.
  51. Remove the 2 nuts and disconnect the 2 wires from the starter solenoid.
  52. Remove the 3 bolts and the starter.

    Click image to see an enlarged view
    Fig. Removing the starter
  53. Drain the engine oil. Install the drain plug and tighten to 19 ft. lbs. (26 Nm).
  54. Remove and discard the engine oil filter.
    NOTE
    Use a steering wheel holding device (such as Hunter®28-75-1 or equivalent).
  55. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
    NOTE
    Do not allow the steering wheel to rotate while the steering column intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the wheel has rotated, the clockspring must be removed and recentered.
  56. Remove the upper bolt from the intermediate steering shaft. Position the intermediate steering shaft aside.
  57. Remove the clutch disc and pressure plate.
  58. Remove the bolt and the ground wire from the rear of the LH cylinder head.
  59. Install the Engine Lifting Bracket.
  60. Remove the RH engine support insulator nut.
  61. Remove the LH engine support insulator nut.
  62. Install the Heavy Duty Floor Crane and the Engine Lifting Bracket. Remove the engine from the vehicle.
To install:

WARNING
Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

  1. Using the Heavy Duty Floor Crane and the Engine Lifting Bracket, install the engine into the vehicle.
  2. Install the LH engine insulator nut. Tighten to 46 ft. lbs. (63 Nm).
  3. Install the RH engine insulator nut. Tighten to 46 ft. lbs. (63 Nm).
  4. Install the ground wire and the bolt to the rear of the LH cylinder head. Tighten to 89 inch lbs. (10 Nm).
  5. Install the clutch disc and pressure plate.
    NOTE
    Do not allow the steering wheel to rotate while the steering column intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the wheel has rotated, the clockspring must be removed and recentered.
  6. Install the intermediate steering shaft and the upper bolt. Tighten to 35 ft. lbs. (47 Nm).
  7. Install a new engine oil filter in the following sequence.
    1. Lubricate the oil filter gasket with clean engine oil and tighten until the seal makes contact.
    2. Using an oil filter strap wrench, tighten the filter an additional 270°.
      NOTE
      For correct starter installation, the upper bolt must be tightened first.


      NOTE
      Clean the starter motor mounting flange and mating surface of the starter motor to make sure there is a correct ground connection.
  8. Install the starter and the 3 bolts finger-tight.
    1. Tighten the upper bolt to 18 ft. lbs. (25 Nm).
    2. Tighten the 2 lower bolts to 18 ft. lbs. (25 Nm).

      Click image to see an enlarged view
      Fig. Installing the starter
  9. Connect the 2 wires and install the 2 nuts on the starter solenoid.
    1. Tighten the B+ terminal to 106 inch lbs. (12 Nm).
    2. Tighten the S-terminal to 44 inch lbs. (5 Nm).
  10. Install the starter solenoid terminal cover.
  11. Attach the 2 wiring harness pin-type retainers to the oil pan.
  12. Install the ground wire and the nut to the RH engine insulator bracket stud bolt. Tighten to 18 ft. lbs. (25 Nm).
  13. Install the A/C compressor and the 3 stud bolts. Tighten to 18 ft. lbs. (25 Nm).
  14. Position the Supercharger (SC) drive onto the A/C compressor and attach the 2 wiring harness retainers onto the A/C compressor stud bolts.
  15. Attach the wiring harness pin-type retainer to the back of the A/C compressor.
  16. Connect the A/C compressor electrical connector.
  17. Attach the wire harness retainer to the A/C compressor stud bolt.
  18. Connect the Crankshaft Position (CKP) sensor electrical connector.
  19. Install the wire harness bracket to the oil pan stud bolt and install the nut. Tighten to 89 inch lbs. (10 Nm).
  20. Attach the wiring harness retainer to the oil pan stud bolt.
  21. Connect the B+ wire to the generator and install the nut. Tighten to 71 inch lbs. (8 Nm).
  22. Connect the power steering return hose.
    NOTE
    A new Teflon® seal must be installed.
  23. Using the Teflon® Seal Installer Set, install a new Teflon® seal on the Power Steering Pressure (PSP) tube fitting.
  24. Connect the pressure PSP tube fitting. Tighten to 48 ft. lbs. (65 Nm).
  25. Position the lower radiator hose assembly into the vehicle. Connect the lower radiator hose to the radiator.
  26. Connect the coolant hose to the oil cooler.
  27. Rotate the SC drive belt tensioner clockwise and install the drive belt onto the SC drive pulley.

    Click image to see an enlarged view
    Fig. Rotating the SC drive belt tensioner clockwise and installing the drive belt onto the SC drive pulley
  28. Connect the A/C pressure transducer electrical connector.
  29. Connect the hose to the power steering reservoir.
  30. Connect the 16-pin electrical connector and attach the 2 wiring retainers
  31. Connect the upper and lower PCM electrical connectors.
  32. Connect the 68-pin connector to the Power Distribution Box (PDB). Tighten to 53 inch lbs. (6 Nm). Attach the PDB upper housing to the lower housing.
  33. Install the PDB cover.
  34. Attach the 2 wiring harness pin-type retainers.
  35. Attach the pin-type wire harness retainer to the cowl.
  36. Connect the 2 heater hoses to the coolant tube assembly at the rear of the engine.
  37. Install the Evaporative Emission (EVAP) canister purge valve.
    1. Connect the lower EVAP tube and electrical connector to the EVAP canister purge valve.
  38. Connect the EVAP tube and brake booster vacuum supply tube to the Throttle Body (TB) spacer.
  39. Connect the fuel supply tube.
  40. Connect the coolant hose to the coolant pump.
  41. Connect the coolant hose to the thermostat housing.
  42. Connect the coolant hose to the coolant tube assembly (above the generator).
  43. Connect the coolant hose from the Charge Air Cooler (CAC).
  44. Install the cooling fan assembly and the 2 bolts. Tighten to 80 inch lbs. (9 Nm).
  45. Connect the cooling fan electrical connector.
  46. Connect the upper radiator hose from the thermostat housing.
  47. Install the SC coolant degas bottle.
  48. Install the engine coolant degas bottle.
  49. Install the 2 steering column dash boot nuts. Tighten to 80 inch lbs. (9 Nm).
  50. Install the battery tray and battery.
  51. Install the Air Cleaner (ACL) and ACL outlet pipe.
    NOTE
    Use the hood hinge location index marks made during removal to aid in hood installation.
  52. Install the hood and 4 bolts. Tighten to 106 inch lbs. (12 Nm).
  53. Connect the windshield washer hose and position the hood insulation.
  54. Install the hood insulation pin-type retainer and attach the 2 windshield washer hose retainers.
  55. Install the strut tower cross brace and the 4 nuts. Tighten to 26 ft. lbs. (35 Nm).
  56. Fill the engine with clean engine oil.
  57. Install the battery and tray.
  58. Fill and bleed the engine cooling system.
  59. Fill and bleed the SC cooling system.
  60. Fill the power steering 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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