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How To replace 4.2L Engine on Ford Truck?


The procedure is similar for both ford and Lincoln car models:-----

The procedure is for Ford Model F series Trucks.
And Lincoln Mark LT model vehicles.
F150 1/2 ton P/U 2WD/ 4WD
F250 Super Duty P/U 2WD/4WD
F350 Super Duty P/U 2WD/4WD
F450 Super Duty P/U 2WD/4WD
F550 Super Duty P/U 2WD/4WD

The procedure to replace 4.2 L engine is as follows:----

Removal & Installation



4.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
All vehicles
  1. Raise and safely support the vehicle.
  2. Release the fuel system pressure.
  3. Disconnect the battery ground cable.
  4. Drain the cooling system.
  5. Remove the hood.
  6. Remove the cowl panel grille.
  7. Remove the powertrain control module (PCM).
  8. Detach the electrical connector, the wiring harness retainer and the washer hose from the cowl extension panel.
Vehicles equipped with a manual transmission
  1. Remove the push pins and position the clutch master cylinder reservoir aside.
  2. Disconnect the fuel vapor tubes from the purge valve.
All vehicles
  1. Remove the 7 bolts and the cowl extension panel.
  2. Remove the 9 push pins and the radiator sight shield.
  3. Remove the upper intake manifold.
  4. Remove the radiator, the cooling fan and the shroud.
  5. Remove the air cleaner.
  6. Release the clamp and disconnect the upper radiator hose from the thermostat housing. Remove the hose from the vehicle.
  7. Release the clamps, disconnect the heater hoses and position the heater hoses aside.
  8. Release the clamp and disconnect the lower radiator hose from the coolant pump.
  9. Disconnect the intake manifold runner control (IMRC) actuator and the fuel charging wiring harness electrical connectors.
  10. Disconnect the fuel supply spring lock coupling.
  11. Remove the 4 bolts and the fuel rail, the fuel injectors, the fuel charging wiring harness and the vacuum harness as an assembly.
Vehicles equipped with an automatic transmission
  1. Disconnect the fuel vapor tubes from the purge valve.
All vehicles
  1. Using the special tool, with a twisting motion, pull the left spark plug wires off the spark plugs.
  2. Detach the left spark plug wire retainers and remove the left spark plug wires.
  3. Remove the bolts and position the power steering fluid reservoir aside.
  4. If equipped, remove the compressor manifold and tube assembly.
  5. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
  6. Remove the 2 power steering pump upper bolts.
  7. Disconnect the alternator.
  8. Detach the wiring harness retainer.
  9. Using the special tool, with a twisting motion, pull the right spark plug wires off the spark plugs.
  10. Detach the right spark plug wire retainers.
  11. Disconnect the coil electrical connector.
  12. Remove the bolts, the coil and the right spark plug wires as an assembly.
  13. Disconnect the positive crankcase ventilation (PCV) valve hose from the PCV valve and remove the hose.
  14. Disconnect the wiring harness in-line connector.
  15. Remove the bolt and detach the ground wire.
  16. Detach the wiring harness retainer from the rear of the right cylinder head.
  17. Remove the power steering pressure hose bracket nut.
    NOTE
    The front bolt cannot be removed from the power steering pump with the pressure hose in place. Remove the rear bolt first, then slide the power steering pump out while removing the second bolt.
  18. Remove the bolts and position the power steering pump aside.
  19. Drain the engine oil. Install the drain plug when finished. Tighten to 23 Nm (17 ft. lbs.).
  20. Remove the oil filter.
Vehicles equipped with an automatic transmission
  1. Detach the transmission cooler tubes from the bracket.
All vehicles
  1. Remove the nut and position the starter wiring harness aside.
  2. If equipped, disconnect the engine block heater electrical connector.
  3. Remove the 4 3-way catalytic converter-to-exhaust manifold nuts.
  4. Remove the starter motor.
Vehicles equipped with an automatic transmission
  1. Remove the cylinder block opening cover.
    NOTE
    Rotate the crankshaft using the crankshaft pulley bolt to access all of the torque converter nuts.


    NOTE
    Mark the flexplate and one torque converter stud for installation reference.
  2. Remove the 4 torque converter nuts.
  3. Remove the 3 oil pan-to-transmission bolts.
  4. Remove the transmission-to-engine bolts.
  5. Remove the left engine support insulator through bolt.
  6. Remove the right engine support insulator nuts.
  7. Remove the stud bolt, the bolts and the power steering fluid reservoir bracket.
  8. Remove the nuts and the right engine lifting eye.
  9. Install the lifting eye on the right side of the engine.
  10. Remove the nuts and the left engine lifting eye.
  11. Install the lifting eye on the left side of the engine.
    NOTE
    Use 2 10mm ( 3 / 8 inch) spring links to connect the Engine Lifting Bracket 303-F047 to the Lifting Bracket, Engine 303-050.
  12. Install the lifting bracket.
  13. Connect an engine crane to the special tool and lift the engine approximately 75 mm (3 in.).
  14. Remove the bolts and the left engine support insulator.
  15. Remove the bolts and the right engine support insulator.
  16. Support the transmission with a floor jack and a wood block.
Vehicles equipped with an automatic transmission
  1. Remove the engine from the vehicle.
Vehicles equipped with a manual transmission
  1. Lift the engine while pulling the engine forward until the alternator pulley is above the radiator upper support.
  2. Rotate the engine 90 degrees to the left and remove the engine from the vehicle.
To install:
Vehicles equipped with an automatic transmission

NOTE
Make sure the marks made on the torque converter stud and the flexplate are lined up.

  1. Position the engine in the vehicle and mate it to the transmission.
Vehicles equipped with a manual transmission
  1. Position the engine with the front of the engine facing the left side of the vehicle.
  2. Lower the engine until the alternator pulley is slightly higher than the radiator upper support.
  3. Turn the engine 90 degrees to the right, lower the engine and mate it to the transmission.
All vehicles
  1. Install the right engine support insulator and the bolts. Tighten to 63 Nm (46 ft. lbs.).
  2. Install the left engine support insulator and the bolts. Tighten to 63 Nm (46 ft. lbs.).
  3. Remove the floor jack and wood block from the transmission.
  4. Lower the engine into position and remove the floor crane and the special tools.
  5. Position the power steering fluid reservoir bracket and install the bolts and the stud bolt. Tighten to 20 Nm (15 inch lbs.).
  6. Install the right engine support insulator nuts. Tighten to 175 Nm (129 ft. lbs.).
  7. Install the left engine support insulator through bolt. Tighten to 175 Nm (129 ft. lbs.).
  8. Install the transmission-to-engine bolts. Tighten to 47 Nm (35 ft. lbs.).
  9. Install the 3 oil pan-to-transmission bolts. Tighten to 34 Nm (24 ft. lbs.).
Vehicles equipped with an automatic transmission

NOTE
Rotate the crankshaft using the crankshaft pulley bolt to access all of the torque converter nuts.

  1. Install the 4 torque converter nuts. Tighten to 36 Nm (27 ft. lbs.).
  2. Install the cylinder block opening cover.
All vehicles
  1. Install the starter motor.
  2. Install the 4 3-way catalytic converter nuts. Tighten to 40 Nm (30 ft. lbs.).
  3. If equipped, connect the engine block heater electrical connector.
  4. Position the starter wiring harness bracket and install the nut. Tighten to 20 Nm (15 ft. lbs.).
Vehicles equipped with an automatic transmission
  1. Attach the transmission cooler tubes to the bracket.
All vehicles
  1. Install a new oil filter. Tighten to 12 Nm (9 ft. lbs.).
    NOTE
    Do not tighten the bolts until the 2 upper bolts are installed.


    NOTE
    Make sure the power steering pressure hose bracket is installed on the stud.
  2. Position the power steering pump and install the bolts finger tight. Install the nut. Tighten to 10 Nm (89 inch lbs.).
  3. Attach the wiring harness retainer to the rear of the right cylinder head.
  4. Position the ground wire and install the bolt.
  5. Connect the wiring harness in-line connector.
  6. Connect the positive crankcase ventilation (PCV) valve hose to the PCV valve.
  7. Position the coil and the right spark plug wires as an assembly and install the bolts. Tighten to 7 Nm (62 inch lbs.).
  8. Connect the coil electrical connector.
  9. Attach the right spark plug wire retainers.
  10. Apply silicone dielectric compound to the inside of the spark plug wire boots.
  11. Connect the spark plug wires to the spark plugs. Attach the wiring harness retainer.
  12. Connect the alternator.
    NOTE
    Tighten the lower bolts at this time.
  13. Install the power steering pump upper bolts. Tighten to 25 Nm (18 ft. lbs.).
  14. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
  15. If equipped, install the compressor manifold and tube assembly.
  16. Position the power steering fluid reservoir and install the bolts. Tighten to 10 Nm (89 inch lbs.).
  17. Position the left spark plug wires and attach the left spark plug wire retainers.
  18. Apply silicone dielectric compound to the inside of the spark plug wire boots.
  19. Connect the spark plug wires to the spark plugs.
Vehicles equipped with an automatic transmission
  1. Connect the fuel vapor tubes to the purge valve.
All vehicles
  1. Position the fuel rail, the fuel injectors, the fuel charging wiring harness and the vacuum harness as an assembly and install the bolts. Tighten to 10 Nm (89 inch lbs.).
  2. Connect the fuel supply spring lock coupling.
  3. Connect the intake manifold runner control (IMRC) actuator and the fuel charging wiring harness electrical connectors.
  4. Connect the lower radiator hose to the coolant pump.
  5. Connect the heater hoses.
  6. Connect the upper radiator hose to the thermostat housing.
  7. Install the air cleaner.
  8. Install the radiator and the cooling fan and shroud.
  9. Install the upper intake manifold.
  10. Position the radiator sight shield and install the 9 push pins.
  11. Position the cowl extension panel and install the 7 bolts.
Vehicles equipped with a manual transmission
  1. Connect the fuel vapor tubes to the purge valve. Position the clutch master cylinder reservoir and install the push pins.
All vehicles
  1. Attach the windshield washer hose, the wiring harness retainer and the electrical connector to the cowl extension panel.
  2. Install the powertrain control module (PCM).
  3. Install the cowl panel grille.
  4. Position the hood and install the bolts. Tighten to 30 Nm (22 ft. lbs.).
  5. Connect the battery ground cable.
  6. Fill the engine with clean engine oil.
  7. Fill and bleed the cooling system.
  8. If equipped, evacuate and charge the A/C 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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