Engine: Service and Repair Engine Steps 1 - 50 › kwiggins29059 › 11139876-b87b...101. Remove the bolts and the RH radiator support bracket. 102. Remove the radiator and A/C condenser

2002 Ford Truck Explorer 4WD V6-4.0L VIN K Flex Fuel Copyright © 2013, ALLDATA 10.52 Page 1

Engine: Service and RepairEngine

Steps 1 - 50REMOVAL

Special Tools

Special Tool(s)

Removal

CAUTION: If the supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when workingaround the fuel supply manifold.

All vehicles 1. Disconnect the battery ground cable. 2. Remove the hood.3. Remove the cooling fan. 4. Discharge and recover the A/C system. 5. Relieve the fuel pressure.

6. Open the power distribution box cover.


7. Disconnect the battery cable and cable retainer.8. Remove the power steering pump pulley. 9. Remove the air cleaner outlet pipe.

10. Disconnect the Mass Air Flow (MAF) sensor electrical connector.

11. Remove the air cleaner assembly.

12. Disconnect the Powertrain Control Module (PCM) electrical connectors.13. Release the fuel charging wiring harness from the clips on the bulkhead.


14. Disconnect the transmission control wiring harness pin-type retainers from the fuel charging wiring harness.15. Disconnect the fuel tube.

16. Disconnect the vacuum hose.

17. Remove the ground wire from the engine.18. Drain the cooling system.

19. Disconnect the vacuum hose and the heater hose.


20. Remove the bolts and position the heater hose bracket aside.

21. Disconnect the upper radiator hose.

22. Disconnect the lower radiator hose at the water pump1 Release the clamp.2 Remove the radiator hose.

23. Disconnect the coolant hoses from the degas bottle.


24. Disconnect the A/C tube from the accumulator.- Discard the O-ring.

25. Remove the nut and disconnect the A/C tube from the condenser.

26. Disconnect the accelerator and the speed control cables from the throttle body.

27. Remove the accelerator cable from the accelerator cable retainers.


28. Remove the accelerator and the speed control cables from the bracket and position aside.

29. Disconnect the vacuum hoses.

30. Disconnect the A/C high-pressure cut-off switch electrical connector.

31. Remove the nut and disconnect the A/C tube from the condenser.- Discard the O-ring.


32. Disconnect the A/C tube from the retainer. 33. Remove the exhaust gas recirculation (EGR) tube.

34. Tap the hole in the RH cylinder head in order to install the lifting hook. Use a 10 x 1.5 mm (6 inch) tap to tap the hole.

35. Install the lifting eye in the tapped hole.

36. Install the special tools.


37. Attach the special tools.

Manual transmission

38. NOTE: Do not remove the gearshift lever knob.

Remove the screw and lift the console finish panel to access the gearshift lever nut. Remove the gearshift lever nut, then remove the uppergearshift lever and console finish panel as an assembly.- Install the nut on the front of the lever, and then tighten the nut to remove the eccentric stud out of the gearshift lever.

39. Remove the bolt and shaft.

All vehicles 40. Raise and support the vehicle. 41. Remove the starter.


42. Remove the pushpins and the lower air shroud panel.

Manual transmission 43. Remove the skid plate, if equipped.

44. Disconnect the vent tube.

4x4 vehicles 45. Install a suitable jackstand under the transfer case.

4x2 vehicles

46. WARNING: Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result inpersonal injury.

Support the transmission with a transmission jack.


All vehicles 47. Remove the bolts and position the RH heat shield aside.

48. NOTE: LH shown, RH similar.

Disconnect the two heated oxygen sensor electrical connectors.

49. NOTE: RH shown, LH similar.

Disconnect the two catalyst monitor sensor electrical connectors.

50. Remove the RH heat shield bolts.

Steps 51 - 110


51. Remove the RH heat shield bolt and remove the heat shield.

52. Remove the LH heat shield bolt.

53. Remove the two nuts and the plastic shield on the right side of the crossmember.


Remove the upper crossmember bolts.


55. Remove the bolts, springs, flag nuts and separate the muffler from the converter.- Discard the gasket.- Discard the flag nuts.


Remove the four converter-to-manifold nuts.


Remove the lower crossmember bolts.

4x2 vehicles automatic transmission 58. Remove the bolts and cable bracket from the transmission.


All vehicles 59. Remove the transmission support insulator nuts and remove the crossmember.

60. NOTE: The assistance of another technician may be required.

Remove the transmission-mounted exhaust hanger and the 3-way converter system.1 Remove the bolt and the converter assembly.2 If required, remove the second bolt and mount.

61. Disconnect the shift cable and remove the bracket.

62. Position the manual shift lever out of PARK.


4x4 vehicles 63. Index-mark the front axle pinion flange and the front driveshaft.

64. Index-mark the front output shaft assembly and the front driveshaft Constant Velocity (CV) joint.

65. Remove and discard the bolts and washers.

66. Remove and discard the bolts and universal joint retainers.


67. CAUTION: Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft can pinch the boot andcause the boot to tear.

CAUTION: Tape the bearing cups to the driveshaft to prevent them from falling off the spider.

Remove the front driveshaft.

All vehicles

68. NOTE: Axle pinion flange shown, transfer case output flange similar, if equipped.

Remove the rear driveshaft bolts.1 Mark the location of the flanges.2 Remove the bolts.

69. CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components todisconnect the driveshaft flange from the pinion flange.

NOTE: Use a suitable plug to prevent fluid loss on 2WD vehicles.

Using a suitable tool as shown, disconnect the driveshaft flange and remove the driveshaft.


70. Remove the lower transmission retaining bolts.

71. Disconnect the RH catalyst monitor connector and the fuel lines from the bracket.

72. Disconnect the RH heated oxygen sensor electrical connector from the transmission.

73. If equipped, disconnect the shift motor electrical connector.


74. Disconnect the LH heated oxygen sensor electrical connector retainer and the harness clip from the transmission.

75. Disconnect the LH catalyst monitor connector from the transmission.

Automatic transmission

76. NOTE: Make an identifying mark on the nut, stud and flexplate to allow for correct installation.

Remove the four torque converter nuts.

77. Move the rubber boot back to gain access to the connector.


78. Disconnect the digital transmission range sensor.

79. Disconnect the electrical connectors.

80. NOTE: Clean the area around the connector to prevent contamination of the solenoid body connector.

Remove the screw and disconnect the solenoid body electrical connector.

81. Disconnect the harness retainers.


82. CAUTION: Do not damage the cooler tubes. Hold the transmission case fitting with a wrench.

Disconnect the transmission cooler tubes.

4x4 manual transmission

83. WARNING: Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result inpersonal injury.

Support the transmission with a transmission jack.84. Remove the jackstand from under the transfer case.

85. CAUTION: Position a suitable drain pan below the extension housing.

Remove the seven bolts. Separate the transfer case from the extension housing. Lower the transfer case from the vehicle.

Manual transmission 86. Disconnect the clutch hydraulic line from the clutch slave cylinder.

87. Disconnect the Output Shaft Speed (OSS) sensor electrical connector and the electrical connector from the transmission.


88. Disconnect the reverse lamp switch electrical connector and disconnect the connector from the transmission.

Automatic transmission 89. Disconnect the cooler lines and allow them to drain into a suitable container.

90. Remove the nut and the cooler lines and the cooler line bracket.

All vehicles 91. Remove the engine-to-transmission retaining bolts.92. Remove the transmission.


93. Disconnect the power steering return hose and allow it to drain into a suitable container.94. Drain the engine oil.

95. Remove the LH engine support insulator bolt.96. Lower the vehicle.

97. Remove the bolt and power steering line support bracket.

98. Disconnect the power steering pressure line from the power steering pump.99. Remove the engine support bar.


100. Remove the bolt and the LH radiator support bracket.

101. Remove the bolts and the RH radiator support bracket.102. Remove the radiator and A/C condenser as an assembly.

103. Remove the RH engine support insulator nuts.

104. Install the right side Lifting Eye.

105. Install the left side Lifting Eye.106. Install the Spreader Bar to the Lifting Eyes.


107. Attach a floor crane to the Spreader Bar and remove the engine.

108. Remove the flywheel.109. Remove the spacer plate.110. Install the engine on a suitable engine stand.

Steps 1 - 50DISASSEMBLY


Special Tool(s)


1. Remove the nuts and the A/C hose.2. Rotate the drive belt tensioner counterclockwise and remove the drive belt.


3. Remove the bolts.

4. Remove the bolts and position the accessory bracket aside.

5. Remove the generator mounting bracket. 1 Remove the drive belt tensioner bolt. 2 Remove the generator mounting bracket bolts.

6. Disconnect the following:- Camshaft Position (CMP) sensor electrical connector.- Ignition coil electrical connector.- Pin-type retainer.


7. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires.

NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them.

Remove the right side spark plug wires.

8. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires.

NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them.

Remove the left side spark plug wires.

9. Remove the bolts and the coil and bracket assembly.

10. Remove the hose.


11. Disconnect the upper radiator hose from the thermostat housing.

12. Remove the heater hose from the thermostat housing.

13. Release the hose clamp and remove the lower radiator hose.

14. Release the hose clamp and remove the lower heater water hose.

15. Disconnect the heater control valve vacuum hose.


16. Remove the bracket bolt and the heater water hose.

17. Remove the coolant tube.

18. Remove the Exhaust Gas Recirculation (EGR) tube.19. Remove fuel supply tube retaining bolt from the right valve cover.

20. Remove the hose.


21. Disconnect the right side fuel injector electrical connectors.

22. Disconnect the left side fuel injector electrical connectors.

23. Disconnect the coolant temperature sensor electrical connector.

24. Remove the wiring anchors.


25. Disconnect the Crankshaft Position (CKP) sensor electrical connector.

26. Remove the fuel charging wiring harness retainers.

27. Remove the fuel charging wiring harness.

28. Disconnect the fuel pulse damper vacuum hose and remove the vacuum harness.


29. Remove the fuel injection supply manifold.

30. Remove the LH valve cover.

31. Remove the RH valve cover.

32. Remove the fuel injectors.

33. Remove the thermostat housing. 1 Remove the bolts. 2 Release the bypass hose clamp.


34. Remove the oil level indicator tube.

35. Remove the knock sensor.

36. Remove the RH exhaust manifold and the gasket.

37. Remove the LH exhaust manifold and the gasket.


38. Remove the water pump.

39. Remove the bolt.

40. Using the special tool, remove the crankshaft pulley.

41. Remove the RH hydraulic chain tensioner.


42. NOTE: Mark each camshaft roller follower to make sure it is installed in its original position during reassembly.

Using the special tool, remove the camshaft roller followers.

43. CAUTION: The right-hand camshaft sprocket bolt is a left-hand threaded bolt.

Remove the RH camshaft sprocket bolt.

44. Remove the camshaft sprocket from the camshaft and install a rubber band on the cassette to hold the chain and camshaft sprocket in place.



46. Remove the LH hydraulic chain tensioner.

47. Remove the LH camshaft sprocket bolt.

48. Remove the camshaft sprocket from the camshaft and install a rubber band on the cassette to hold the chain and camshaft sprocket in place.



50. Remove the bolts in the sequence shown and remove the LH cylinder head.

Steps 51 - 87

51. Remove the bolts in the sequence shown and remove the RH cylinder head.

52. Remove the engine front cover.

53. Remove the oil pan.


54. Remove the oil pump screen cover and tube.


56. Remove the ladder frame bolts.

57. Remove the 15 bolts and the two nuts. Remove the ladder frame.


58. Remove the oil pump.59. Remove the oil filter.

60. Remove the oil filter adapter.

61. Inspect and install new O-ring seals if necessary.

62. Remove the chain tensioner.


63. Remove the chain guide.

64. Remove the rear jackshaft plug.

65. Install the special tool at the rear of the jackshaft.

66. Loosen the front sprocket retaining bolt.67. With the special tool still in place, loosen the rear sprocket retaining bolt.68. Remove the special tool.


69. NOTE: It may be required to hold the oil pump intermediate shaft, using an E-12 external TORX socket, in order to remove the bolts if the boltsdo not turn out easily at this time.

Remove the bolt.

70. Remove the jackshaft sprocket and chain.

71. Remove the bolt and the front cassette.

72. Remove the bolt and spacer.


73. Remove the bolt and remove the cassette.

74. Remove the oil pump drive.

75. Remove the jackshaft thrust plate.

76. Remove the jackshaft.


77. On 4x4 vehicles, remove the balance shaft tensioner.1 Install a pin in the balance shaft tensioner.2 Remove the bolts.3 Remove the balance shaft tensioner.

78. NOTE: DO NOT remove the balance shaft sprocket bolt.

On 4x4 vehicles, remove the balance shaft chain and crankshaft sprocket.

79. 0n 4x4 vehicles, remove the balance shaft. 1 Remove the bolts. 2 Remove the balance shaft.

80. Using the cylinder ridge reamer, remove the ridge and carbon deposits from the top of each cylinder.


81. Remove the piston and connecting rod assemblies.1 Remove the connecting rod nuts. 2 Remove the connecting rod cap.

82. Install rubber hose pieces on the bolts to protect the crankshaft and remove the pistons.


84. Remove the crankshaft main bearing caps.


85. Remove the crankshaft rear oil seal from the crankshaft.

86. Remove the crankshaft.87. Remove the crankshaft main bearings and the thrust bearing.

Steps 1 - 60

NOTE: Ford does not provide timing marks or additional information for servicing of the timing chains/sprockets without the special tools listed inthis procedure.

ASSEMBLY


Special Tool(s)


NOTE: Before engine assembly, use metal surface cleaner and a suitable plastic or wooden scraper to clean the sealing surfaces. All sealing surfacesmust be clean. Make sure coolant and oil passages are clear.

1. Install the crankshaft main bearings and the thrust bearing.- Lubricate the crankshaft main bearings with clean engine oil.


2. NOTE: The crankshaft main bearings are precision selective fit. Inspect the bearing clearance.

Install the crankshaft.

3. NOTE: The rear main bearing cap must be installed within four minutes after applying the silicone.

Apply silicone gasket and sealant to the rear main bearing cap to cylinder block parting line.4. Install the crankshaft lower main bearings in the main bearing caps.

5. Install the main bearing caps.

6. Tighten the bolts.7. Lubricate the piston rings with clean engine oil.8. Make sure that the piston rings are correctly spaced.


9. Install rubber hose pieces on the connecting rod bolts to protect the crankshaft.

10. NOTE: Position the piston with the indentation arrow toward the front of the cylinder block.

Using the special tool, install the pistons.

11. NOTE: The old nuts and bolts are used for checking clearances. New nuts and bolts must be used for reassembly.

Check the clearance of each connecting rod bearing. 12. Rotate the crankshaft until the piston is at the bottom of its stroke.

13. NOTE: For cylinders 1, 2, and 3, remove the connecting rod nut at the oil split hole side first.

For cylinders 4, 5, and 6, remove the opposite nut first.Loosen the first nut until the face is approximately 2 mm (0.08 inch) over the end of the bolt.

14. Tap the bolt on the nut until it can be removed by hand.15. Repeat previous two steps for the opposite bolt.


16. Install the new bolts making certain that the bolt head is parallel to the side face of the connecting rod.17. Install the connecting rod cap in the original position.

18. Install and tighten the connecting rod nuts finger tight.19. Tighten the connecting rod nuts simultaneously in two stages:

- Stage 1: Tighten 20 Nm (15 ft. lbs.). - Stage 2: Tighten 90 degrees.

20. Repeat previous four steps for the remaining connecting rods.21. Rotate crankshaft until No. 1 piston is at top dead center.

22. On 4x4 vehicles, install the balance shaft. 1 Install the balance shaft assembly.2 Install the bolts.

23. On 4x4 vehicles, install the balance shaft chain and crankshaft sprocket.


24. NOTE: Due to the gear ratio between the reversal shaft and the balance shaft, up to seven complete turns of the balance shaft may be required tofind the correct position.

On 4x4 vehicles, align the timing marks.- Install a 4 mm (0.16 inch) pin to hold the shaft in place.

25. On 4x4 vehicles, install the balance shaft tensioner.1 Install the balance shaft tensioner.2 Install the bolts.3 Position the balance shaft chain guide and install the two bolts.

- Remove the pin from the tensioner.

26. Install the oil pump.

27. Install the jackshaft.


28. Install the jackshaft thrust plate and bolts.

29. Install the oil pump drive.

30. Attach the rear cassette and sprocket to the cam. Do not tighten the bolt at this time.

31. Install the rear cassette and bolt.


32. Install the front cassette and bolt.

33. Position the jackshaft sprocket and chain.

34. Install the chain guide.

35. Install the chain tensioner.


36. Install the bolt. Do not tighten at this time.37. While holding the front jackshaft sprocket bolt secure, tighten the rear bolt to 20 Nm (15 ft. lbs.).

38. Install the special tool on the rear of the jackshaft.

39. Tighten the rear bolt an additional 90 degrees.

40. Tighten the front bolt in two stages.- Stage 1: Tighten to 45 Nm (33 ft. lbs.). - Stage 2: Tighten 90 degrees.


41. Remove the special tool and install the rear jackshaft plug.

42. Position the front cover gasket and install the front cover.

43. Apply silicone gasket and sealant to the front cover in four places.

44. Apply silicone gasket and sealant to the rear main bearing cap as shown.- Position the ladder frame gasket.


45. CAUTION: The ladder frame inserts must be loosened completely or damage to the ladder frame and/or oil leaks may result.

Loosen the ladder frame inserts.

46. Position the ladder frame and gasket assembly.

47. Install and hand tighten the fifteen bolts and two nuts.

48. Install and hand tighten the bolts.


49. NOTE: The ladder frame to cylinder block alignment must be within a maximum mismatch of 0.25 mm (0.01 inch) ladder frame underflush or0.05 mm (0.00196 inch) ladder frame protrusion.

Using a straightedge, align the transmission face of the ladder frame with the rear face of the cylinder block.

50. Tighten the fifteen bolts and two nuts.

51. Tighten the bolts.

52. Tighten the inserts.


53. Install new seals on the two silver bolts and position them in the ladder frame.

54. Position the six remaining bolts.

55. Tighten the ladder frame bolts in two stages.- Stage 1: Tighten to 15 Nm (11 ft. lbs.). - Stage 2: Tighten to 33 Nm (24 ft. lbs.).

56. NOTE: Assemblies that measure out of specification must have the entire assembly procedure repeated.

Measure the step between the rear face of the cylinder block and the transmission face of the ladder frame.


57. Repair all assemblies that exceed underflush specification by installing shims on one or both sides of the ladder frame.

58. Install the oil pump screen cover and tube.

59. Install the gasket, and the oil pan.

60. Install the oil filter adapter.

Steps 61 - 125

NOTE: Ford does not provide timing marks or additional information for servicing of the timing chains/sprockets without the special tools listed inthis procedure.


61. Install the oil filter.

62. Install the water pump.


Install the cylinder head gasket.


Install the cylinder head and tighten the bolts in the sequence shown.



Install the two 8 mm bolts.


Tighten the bolts in the sequence shown in three stages.- Stage 1: Tighten fasteners 1-4 to 32 Nm (24 ft. lbs.). - Stage 2: Tighten fasteners 5-8 to 32 Nm (24 ft. lbs.). - Stage 2: Rotate an additional 90 degrees.

67. Using the special tool, install the crankshaft pulley.

68. CAUTION: A new bolt must be used each time it is removed.


Tighten the bolt in two stages.- Stage 1: Tighten to 50 Nm (37 ft. lbs.). - Stage 2: Rotate an additional 90 degrees.

69. CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.

Install the RH rear camshaft bolt.

70. Install the bolt.

71. CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.

Install the LH front camshaft bolt.

72. Install the bolt.73. Turn the crankshaft one revolution clockwise.


74. NOTE: The special tool must be installed on the damper and should contact the engine block, this positions the engine at Top Dead Center(TDC).

Install the special tool.

75. NOTE: Camshaft timing slots are off-center.

NOTE: Position the camshaft timing slots below centerline of camshaft to correctly fit the special tools.

Install the special tools on the front of the RH cylinder head.

76. NOTE: Leave the top two special tool clamp bolts loose.

Install the special tools on the rear of the RH cylinder head.

77. Install the special tool.


78. CAUTION: The right-hand camshaft sprocket bolt is a left-hand threaded bolt.

Tighten the bolts.1 Tighten the special tool top two clamp bolts to 10 Nm (89 inch lbs.). 2 Tighten the camshaft bolt.

79. Remove the special tool and install the RH camshaft tensioner.80. Remove the special tools from the RH cylinder head.

81. NOTE: Do not tighten the special tool top two clamp bolts. Camshaft sprocket must rotate freely.

Install the special tools on the front of the LH cylinder head.

82. NOTE: Camshaft timing slots are off-center.

NOTE: Position the camshaft timing slots below centerline of camshaft to correctly fit the special tools.

Install the special tools on the rear of the LH cylinder head.


83. Install the special tool.

84. Tighten the bolts.1 Tighten the special tool top two clamp bolts to 10 Nm (89 inch lbs.). 2 Tighten the camshaft bolt.

85. Remove the special tool and install the LH camshaft tensioner.86. Remove the special tools from the LH cylinder head.

87. Remove the special tool.


88. NOTE: Lubricate the parts with clean engine oil.

Using the special tool, install the roller followers in their original position.

89. Install the gasket and the RH exhaust manifold.

90. Install the gasket and the LH exhaust manifold.

91. NOTE: Prior to installation, use metal surface cleaner to clean mating surfaces.

Install the knock sensor.


92. Install the oil level indicator tube.

93. Install the thermostat housing. 1 Install the bypass hose onto the water pump. 2 Install the bolts. 3 Position the bypass hose clamp.

94. Install the RH valve cover and gasket.

95. Install the LH valve cover and gasket.


96. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings seals can cause the fuel system to leak. Donot reuse the O-ring seals.

Install new O-ring seals on each of the fuel injectors.

97. NOTE: Lubricate the fuel injector O-ring seals with clean engine oil.

Install the fuel injectors.

98. Install the fuel injection supply manifold.

99. Position the vacuum harness on the engine and connect the fuel pulse damper vacuum hose.


100. Position the fuel charging wiring harness on the engine.

101. Install the fuel charging wiring harness retainers.

102. Connect the Crankshaft Position (CKP) sensor electrical connector.

103. Install the wiring anchors.


104. Connect the coolant temperature sensor electrical connector.

105. Connect the left side fuel injector electrical connectors.

106. Connect the right side fuel injector electrical connectors.

107. Install the hose.108. Install the fuel supply tube to right valve cover retaining bolt.


109. Install the EGR tube.

110. Install the coolant tube.

111. Install the heater water hose and the bracket bolt.

112. Connect the heater control valve vacuum hose.


113. Install the lower heater water hose and clamp.

114. Install the lower radiator hose and clamp.

115. Install the heater hose to the thermostat housing.

116. Connect the upper radiator hose to the thermostat housing.

117. Install the hose.


118. Install the coil and bracket assembly.

119. CAUTION: Make sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifolds. Wire contact can sendvoltage spikes to other electronic modules.

NOTE: Apply silicone dielectric compound to the inside of the spark plug boots.

Connect the left spark plug wires.

120. CAUTION: Make sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifolds. Wire contact can sendvoltage spikes to other electronic modules.

NOTE: Apply silicone dielectric compound to the inside of the spark plug boots.

Connect the right spark plug wires.


121. Connect the following:- Camshaft Position (CMP) sensor electrical connector.- Ignition coil electrical connector.- Pin-type retainer.

122. Install the generator mounting bracket.1 Install the generator mounting bracket bolts.2 Install the drive belt tensioner bolt.

123. Install the accessory bracket and tighten the bolts.124. Rotate the drive belt tensioner counterclockwise and install the drive belt.

125. Install the A/C hose.

Steps 1 - 50INSTALLATION


Special Tools

Special Tool(s)

Installation


All vehicles 1. Install the right side Lifting Eye.

2. Install the left side Lifting Eye.3. Install the Spreader Bar on the Lifting Eyes.4. Attach the floor crane to the Spreader Bar and remove the engine from the engine stand.5. Install the rear crankshaft oil seal. 6. Install the spacer plate. 7. Install the flywheel. 8. Install the engine, remove the floor crane and the Spreader Bar.


9. Install the RH motor mounts.10. Install the radiator and A/C condenser as an assembly.

11. Install the RH radiator support bracket and bolts.

12. Install the LH radiator support bracket and bolts.

13. Install the special tools.


14. Connect the special tools.

15. Connect the power steering pressure hose to the power steering pump.

16. Install the power steering pressure hose support bracket and the bolt.17. Raise and support the vehicle.

18. Install the LH engine support insulator bolt.


19. Connect the power steering return hose.20. Position the transmission.

21. Install the seven engine-to-transmission retaining bolts.

Automatic transmission 22. Install the cooler tubes, cooler line bracket and the nut.

23. Connect the cooler tubes.


Manual transmission 24. Connect the reverse lamp switch electrical connector.

25. Connect the Output Shaft Speed (OSS) sensor electrical connector.

26. Connect the clutch hydraulic tube to the clutch slave cylinder.

4x4 manual transmission 27. Install the transfer case to the extension housing and the seven retaining bolts.28. Support the transfer case with a jackstand.

Automatic transmission 29. Connect the harness retainers.


30. Connect the solenoid body electrical connector and install the screw.

31. Connect the electrical connectors.

32. Connect the digital transmission range sensor.

33. Move the rubber boot back into position.


34. NOTE: Match the identifying mark on the nut, stud and flexplate to allow for correct installation.

Install the four torque converter nuts.

All vehicles 35. Connect the LH catalyst monitor connector to the transmission.

36. Connect the LH heated oxygen sensor electrical connector retainer and the harness clip to the transmission.

37. If equipped, connect the shift motor electrical connector.


38. Connect the RH heated oxygen sensor electrical connector to the transmission.

39. Connect the RH catalyst monitor connector and the fuel lines to the bracket.

40. CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components toconnect the driveshaft flange to the pinion flange.

NOTE: Install new bolts and washers.

Match the location marks and install the rear driveshaft.

4x4 vehicles

41. NOTE: Install new flange bolts and washers.

Position the front driveshaft flange with location marks matching and loosely install retaining bolts finger-tight.


42. NOTE: Use new bolts and U-joint straps.

Install the front driveshaft to the front differential.

43. Tighten the front driveshaft flange bolts in the sequence shown.

All vehicles 44. Position the manual shift lever into PARK.

45. Install the bracket and connect the shift cable.


46. NOTE: The assistance of another technician may be required.

Position the transmission-mounted exhaust hanger and the 3-way converter system.1 Install the bolt and the converter assembly.2 If required, install the second bolt and mount.

47. Install the crossmember and transmission support insulator nuts.

4x4 automatic transmission 48. Install the cable bracket and the bolts to the transmission.

All vehicles


Install the lower crossmember bolts.



Install the four converter-to-manifold nuts.

Steps 51 - 107

51. Connect the muffler to the converter and install the bolts, springs and flag nuts- Install a new gasket.- Install new flag nuts.


Install the upper crossmember bolts.

53. Install the plastic shield and the two nuts on the right side of the crossmember.


54. Install the LH heat shield bolt.

55. Position the RH heat shield and install the bolt.

56. Install the RH heat shield bolts.


Connect the two catalyst monitor sensor electrical connectors.



Connect the two heated oxygen sensor electrical connectors.

59. Install the bolts and the RH heat shield.

4x2 vehicles 60. Remove the transmission jack from the transmission.

4x4 vehicles 61. Remove the jackstand from under the transfer case.

Manual transmission 62. Connect the vent tube.

63. Install the skid plate, if equipped.


All vehicles 64. Position the lower air shroud panel and install the pushpins.65. Install the starter. 66. Lower the vehicle.

Manual transmission 67. Install the shaft and bolt.

68. Position the upper gearshift lever boot and console finish panel into the console, then install the nut.


All vehicles 69. Remove the special tools.70. Remove the lifting eyes.71. Install the Exhaust Gas Recirculation (EGR) tube.

72. Connect the A/C tube to the retainer.

73. Connect the A/C tube to the condenser.- Install a new O-ring seal.

74. Connect the A/C high-pressure cut-off switch electrical connector.

75. Connect the vacuum hoses.


76. Install the accelerator and speed control cables to the bracket.

77. Connect the accelerator cable to the accelerator cable retainers.

78. Connect the accelerator and the speed control cables to the throttle body.

79. Connect the A/C tube to the condenser.- Install a new O-ring seal.


80. Connect the A/C tube to the accumulator.- Install a new O-ring seal.

81. Connect the coolant hoses to the degas bottle.

82. Connect the lower radiator hose at the water pump.

83. Connect the upper radiator hose.


84. Install the heater hose bracket and retaining bolts.

85. Connect the vacuum hose and the heater hose.

86. Install the ground wire to the engine.

87. Connect the vacuum hose. 88. Connect the fuel tube.


89. Connect the transmission control wiring harness pin-type retainers to the fuel charging wiring harness.90. Install the fuel charging wiring harness in the clips on the bulkhead.

91. Connect the Powertrain Control Module (PCM) electrical connectors.92. Install the air cleaner.

93. Connect the Mass Air Flow (MAF) sensor electrical connector. 94. Install the power steering pump pulley.

95. Connect the battery cable to the power distribution box.


96. Close the power distribution box cover.97. Install the fan blade. 98. Install the air cleaner outlet pipe. 99. Install the hood.

100. Connect the battery ground cable.

Manual transmission 101. Fill and bleed the hydraulic clutch master cylinder. 102. Fill the engine with clean engine oil.103. Fill and bleed engine cooling system.

Automatic transmission 104. Carry out the fluid level check for the transmission. 105. Verify that the shift cable is correctly adjusted, if equipped. 106. Check the operation of the transmission and inspect for leaks.

All vehicles 107. Recharge the A/C system.

Engine: Service and Repair Engine Steps 1 - 50 › kwiggins29059 › 11139876-b87b...101. Remove the bolts and the RH radiator support bracket. 102. Remove the radiator and A/C condenser

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