1999 ford f150 service repair manual

2000 Ford Pickup F350 Super Duty 2000-01 ENGINES 4.6L V8 - VIN W & 6

2000-01 ENGINES 4.6L V8 - VIN W & 6

ENGINE IDENTIFICATION Engine is identified by eighth character of Vehicle Identification Number (VIN). See ENGINE IDENTIFICATION CODES table. VIN is located on top of instrument panel, near lower left corner of windshield. VIN is also stamped on Vehicle Certification (VC) label mounted on left door pillar.

Engine code labels are located in engine compartment, in front of radiator and on right valve cover. Label contains engine calibration number, engine build date, engine plant code and engine code.

Emission calibration number label is located on upper radiator shield. This label identifies engine calibration number, engine code number and revision level. Numbers from labels are required when ordering replacement parts.

ENGINE IDENTIFICATION CODES Engine Type Fuel System 4.6L SOHC SFI 4.6L SOHC SFI

Engine Plant Romeo Windsor

VIN Code W 6

Windsor and Romeo engine plants are producing the 4.6L engine. There are several differences between these engines and many parts are not interchangeable.

The best way to determine manufacturer is by the VIN number. VIN W is a Romeo engine. VIN 6 is Windsor engine. There are a couple external differences. The right valve cover on Windsor engine has 14 bolts, Romeo engine has 11 bolts. Also on Windsor engine there is a W stamped on each valve cover in area of camshaft sprocket.

ADJUSTMENTS VALVE CLEARANCE ADJUSTMENT Hydraulic valve lash adjusters are used. No valve adjustment is required.

TROUBLE SHOOTING NOTE:

To trouble shoot engine mechanical components, see ENGINE MECHANICAL in BASIC TROUBLE SHOOTING article in GENERAL INFORMATION.

REMOVAL & INSTALLATION CAUTION: When battery is disconnected, vehicle computer and memory systems Helpmelearn Repair Manuals Wednesday, November 08, 2006 7:36:08 7:35:52 PM

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may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

NOTE:

For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Place mating marks on engine hood and other major assemblies before removal.

FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS WARNING: Fuel system is under pressure. Release pressure before servicing fuel system components.

1. Remove fuel cap to release fuel tank pressure. Connect EFI pressure gauge to relief valve on right rear corner of fuel rail. Release pressure using valve on pressure gauge.

2. Before disconnecting fuel lines, disconnect negative battery cable. To disconnect fuel lines, remove retaining clip from outside of fuel line coupling.

3. Install fuel line disconnect tool on fuel line coupling so it enters cage opening. Push spring lock coupling remover into cage opening to release female fitting from garter spring. Pull couplings apart. Remove fuel line disconnect tool.

4. When installing fuel lines, fit NEW fuel resistant "O" rings (Brown) on fuel lines. Before installing, lightly coat "O" rings with clean engine oil. Clean fittings, and replace garter spring (if necessary).

5. Install female fitting to male fitting and push until garter spring snaps over flared end of female fitting.

Ensure lines lock together and garter spring is over female fitting flared end.

6. Install retaining clip. Install Black retaining clip on fuel supply line and Gray clip on fuel return line.

Ensure horseshoe portion of clip is over coupling. DO NOT install retaining clip over rubber fuel line.

ENGINE Removal (Expedition & F150 Pickup)

WARNING: Ensure air suspension system is shut off prior to hoisting, jacking or towing an air suspension vehicle. Air suspension switch is located behind right kick panel. Failure to do so can result in inflation or deflation of air springs, which may cause vehicle to shift during servicing.

1. Disconnect negative battery cable. Remove hood. Drain cooling system. Remove radiator. Discharge A/C system using approved refrigerant recovery/recycling equipment. Release fuel pressure and disconnect fuel lines. See FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS .

2. On Expedition and Navigator, remove air conditioning condenser and EGR manifold tube. Unclip mega fuse holders from junction block bracket. Disconnect starter relay cables.

3. On all models, remove upper intake manifold. See INTAKE MANIFOLD . Remove bulkhead connector Helpmelearn Repair Manuals Wednesday, November 08, 2006 7:35:52 PM

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cover. Disconnect necessary grounds and harness connectors. Disconnect necessary water and vacuum connections. Unbolt power steering bracket, and position reservoir and bracket assembly aside. Remove ignition coils and brackets.

4. Raise and support vehicle. Remove starter. Remove A/C compressor. Remove transmission cooler line from block mounted clip. Remove transmission inspection cover, torque converter bolts and transmission-to engine bolts. Remove power steering retaining bolts and position power steering pump aside.

5. Disconnect dual-converter "Y" pipe from exhaust manifolds, and position aside. Remove right and left engine mount bolts. Lower vehicle and support transmission. Remove engine from vehicle.

Removal (E150)

1. Disconnect negative battery cable(s). Discharge A/C system using approved refrigerant recovery/recycling equipment. Release fuel pressure and disconnect fuel lines. See FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS .

2. Disconnect necessary harness and ground connections. Remove intake manifold. See INTAKE MANIFOLD . Remove air deflector, radiator grille, radiator grille open panel and upper and lower core supports. Remove radiator, fan shroud and cooling fan.

3. Remove headlight and side marker assemblies. Remove A/C condenser. Remove accessory drive belt.

Drain power steering fluid by disconnecting reservoir hose at power steering pump. Disconnect high pressure hose at power steering pump. Remove lower radiator hose. Disconnect suction hose at receiverdrier.

4. Raise and support vehicle. Disconnect dual-converter "Y" pipe at exhaust manifold. Drain engine oil and remove oil filter. Remove oil cooler. Remove starter. Remove transmission-to-engine bolts.

5. Remove and discard torque converter nuts. Remove engine mount-to-subframe nuts. Lower vehicle.

Remove transmission oil filler tube. Support transmission. Remove engine from vehicle.

Installation (All Models)

1. To install, reverse removal procedure. Tighten all bolts to specification. See TORQUE SPECIFICATIONS .

2. When installing fuel lines, fit NEW fuel resistant "O" rings (Brown) on fuel lines. Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace garter spring (if necessary).

3. Adjust all control cables and fluid levels. Refill cooling system. Evacuate and recharge A/C system.

INTAKE MANIFOLD Removal (Upper & Lower)

1. Disconnect negative battery cable(s). Remove engine cover. Release fuel pressure and disconnect fuel lines. See FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS . Drain cooling system.

Disconnect upper radiator hose from thermostat housing. Remove air cleaner and outlet tube assembly.

Remove throttle body. Remove EGR manifold tube.

2. Disconnect necessary vacuum and water connections. Disconnect necessary wiring connections. Remove spark plug wires. Remove accessory drive belt. Remove alternator. Remove upper intake manifold-toHelpmelearn Repair Manuals Wednesday, November 08, 2006 7:35:52 PM

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head retaining bolts in reverse order of tightening sequence. See Fig. 2 .

3. Lift upper and lower intake manifold assembly. Disconnect electrical connector at manifold tuning valve, and remove intake manifold assembly from vehicle. Remove upper intake manifold-to-lower intake manifold mounting bolts. Remove pushpin retainer from front of manifold insulator. Separate manifold insulator from lower intake manifold. See Fig. 1 . Separate upper and lower intake manifolds.

Installation

1. To install, reverse removal procedure. Use NEW gaskets and "O" rings. Lubricate fuel injector "O" rings with Light Grade Oil (ESE-M2C39-F) before installing.

2.

CAUTION: Intake manifold bolts must be retightened to specification after engine has reached normal operating temperature.

Ensure alignment tabs on intake manifold gaskets align with holes in cylinder head. Tighten upper intake manifold to lower intake manifold bolts to specification in sequence. See Fig. 2 . Tighten upper intake manifold-to-head bolts to specification in sequence. See Fig. 3 . See TORQUE SPECIFICATIONS .

3. When installing fuel lines, fit NEW fuel resistant "O" rings (Brown) on fuel lines. Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace garter spring (if necessary).

4. To install remaining components, reverse removal procedure. Adjust all control cables and fluid levels.

Refill cooling system. When installing spark plug wires, ensure wires are in correct position on coils. See appropriate SERVICE & ADJUSTMENT SPECIFICATIONS article in ENGINE PERFORMANCE.

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Fig. 1: Exploded View Of Upper & Lower Intake Manifold Courtesy of FORD MOTOR CO.

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Fig. 2: Upper Intake Manifold-To-Lower Intake Manifold Bolt Tightening Sequence Courtesy of FORD MOTOR CO.

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Fig. 3: Upper Intake Manifold-To-Head Bolt Tightening Sequence Courtesy of FORD MOTOR CO. EXHAUST MANIFOLD Removal (All Models)

WARNING: Ensure air suspension system is shut off prior to hoisting, jacking or towing an air suspension vehicle. Air suspension switch is located behind right kick panel. Failure to do so can result in inflation or deflation of air springs, which may cause vehicle to shift during servicing.

Raise and support vehicle. Remove front fender splash shield. If removing left side, remove EGR manifold tube and brake vacuum booster hose bracket. On either side, disconnect exhaust manifold flange. Remove exhaust manifold retaining nuts in reverse order of tightening sequence. See Fig. 4 . Remove exhaust manifold and Helpmelearn Repair Manuals Wednesday, November 08, 2006 7:35:52 PM

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gasket.

Installation

To install, reverse removal procedure. Tighten exhaust manifold nuts to specification in sequence. See Fig. 4 .

See TORQUE SPECIFICATIONS .

Fig. 4: Exhaust Manifold Bolt Tightening Sequence Courtesy of FORD MOTOR CO. CYLINDER HEAD CAUTION: If cylinder head-to-block surface refinishing is necessary, DO NOT remove more than .010" (.25 mm) from cylinder head surface.

Removal

Remove the engine. See ENGINE . Remove exhaust manifold. See EXHAUST MANIFOLD . Remove timing chains. See TIMING CHAINS . Disconnect heater hoses. Remove cylinder head bolts in sequence. See Fig. 5 or Fig. 6 . Remove cylinder head and gasket.

Inspection

Check cylinder head for warpage, cracks and damage. Maximum warpage information is not available from manufacturer.

Installation

1. Ensure proper gaskets are installed. Right and left cylinder head gaskets are not interchangeable.

2.

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CAUTION: Position camshaft so valves DO NOT extend below cylinder head surface, or ensure camshaft positioner is installed before installing cylinder head. See Fig. 9 . Install NEW cylinder head bolts. DO NOT reuse bolts.

Coat bolt head-to-cylinder head surfaces with engine oil. DO NOT oil threads of cylinder head bolts.

Ensure rear cylinder head bolts are installed in cylinder head and secured by rubber bands before installing cylinder head. See Fig. 7 . Install cylinder heads.

3. Tighten cylinder head bolts to specification and in sequence. See Fig. 5 or Fig. 6 . See TORQUE SPECIFICATIONS . If camshaft positioner was not used during cylinder head installation, rotate camshafts using flats matched at center of camshaft until both cams are in time. Install Camshaft Positioner (T91P-6256-A) on flats of camshaft. This will prevent camshafts from rotating.

4. Install timing chains. See TIMING CHAINS . To install remaining components, reverse removal procedure.

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Fig. 5: Cylinder Head Bolt Removal & Installation Sequence (Romeo Engine) Courtesy of FORD MOTOR CO.

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Fig. 6: Cylinder Head Bolt Removal & Installation Sequence (Windsor Engine) Courtesy of FORD MOTOR CO.

Fig. 7: Securing Cylinder Head Bolts Courtesy of FORD MOTOR CO. Helpmelearn Repair Manuals Wednesday, November 08, 2006 7:35:52 PM

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Fig. 8: Positioning Crankshaft Courtesy of FORD MOTOR CO.

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Fig. 9: Installing Camshaft Positioner Courtesy of FORD MOTOR CO. VALVE COVERS Removal (Left)

Disconnect negative battery cable(s). Remove air cleaner. On Expedition and F150, unbolt power steering reservoir bracket and position reservoir, and bracket assembly aside. On all models, disconnect PCV hose from valve cover. Remove EGR manifold tube. Disconnect fuel injection electrical connections. Loosen valve cover retaining bolts. Retaining bolts are part of valve cover and should not be removed. Remove valve cover and gasket.

Removal (Right)

On E150, remove air cleaner, oil filler tube and engine cover. On all models, disconnect PCV valve hose from valve cover. Disconnect electrical connections as necessary. Disconnect heater water hose. Loosen valve cover Helpmelearn Repair Manuals Wednesday, November 08, 2006 7:35:52 PM

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retaining bolts. Retaining bolts are part of valve cover and should not be removed. Remove valve cover and gasket.

Installation (Left & Right)

1. Clean sealing surfaces on valve cover and cylinder head. Using gasket adhesive, glue valve cover gasket into valve cover. Apply a bead of silicone gasket adhesive onto seam where cylinder head and front cover meet.

2. Install valve cover and valve cover mounting bolts. To complete installation, reverse removal procedure.

Tighten bolts to specification. See Fig. 10 . See TORQUE SPECIFICATIONS .

3. When installing fuel lines, fit NEW fuel resistant "O" rings (Brown) on fuel lines. Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace garter spring (if necessary).

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Fig. 10: Valve Cover Bolt Tightening Sequence Courtesy of FORD MOTOR CO. FRONT COVER OIL SEAL Helpmelearn Repair Manuals Wednesday, November 08, 2006 7:35:52 PM

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WARNING: Ensure air suspension system is shut off prior to hoisting, jacking or towing an air suspension vehicle. Air suspension switch is located behind right kick panel. Failure to do so can result in inflation or deflation of air springs, which may cause vehicle to shift during servicing.

Removal

1. Disconnect negative battery cable. On E150, remove air cleaner assembly.

2. Raise and support vehicle. Remove crankshaft pulley. Using seal remover, remove oil seal from front cover.

Installation

To install, reverse removal procedure. Lubricate oil seal bore and seal lip with engine oil before installing. Use seal installer to install oil seal. Apply silicone sealant onto keyway of crankshaft damper before installing.

Tighten bolts to specification. See TORQUE SPECIFICATIONS .

FRONT COVER WARNING: Ensure air suspension system is shut off prior to hoisting, jacking or towing an air suspension vehicle. Air suspension switch is located behind right kick panel. Failure to do so can result in inflation or deflation of air springs, which may cause vehicle to shift during servicing.

Removal

1. Disconnect negative battery cable. Remove both valve covers. See VALVE COVERS . Remove radiator.

Remove accessory drive belt. Remove water pump pulley. Raise and support vehicle. Remove power steering pump, and secure aside.

2. Drain engine oil. Remove oil pan-to-front cover bolts. Remove crankshaft damper retaining bolt and washer. Lower vehicle.

3. Remove idler belt pulley. Disconnect crankshaft position sensor and remove sensor. Remove front cover retaining bolts/studs in reverse order of tightening sequence. See Fig. 11 . Remove front cover and gasket.

Installation

To install, reverse removal procedure. Apply sealant at front cover-to-oil pan, cylinder block and valve cover areas. Apply silicone sealant onto keyway of crankshaft damper before installing. Tighten bolts to specification.

See Fig. 11 . See TORQUE SPECIFICATIONS .

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Fig. 11: Front Cover Tightening Sequence Courtesy of FORD MOTOR CO. TIMING CHAINS Removal

1. Remove valve covers. See VALVE COVERS . Remove front cover. See FRONT COVER . Remove crankshaft position sensor pulse wheel from crankshaft.

2.

CAUTION: DO NOT rotate engine with timing chain removed. Damage to valve/piston may result.

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Rotate crankshaft until No. 1 piston is at TDC. This positions crankshaft keyway 45 degrees from vertical position. See Fig. 12 . Camshaft keyways will point toward crankshaft.

3.

CAUTION: Mark component location for reassembly reference. Components must be installed in original locations.

Install Camshaft Positioner (T96T-6256-AR) on flat area near rear of camshaft. See Fig. 9 . Remove retaining bolts, right chain tensioner, right tensioner arm and right chain guide. See Fig. 13 .

4. Remove right timing chain and crankshaft sprocket. Note direction of sprocket for installation reference.

If necessary for clearance, remove retaining bolt, washer, camshaft sprocket and spacer.

5.

CAUTION: DO NOT rotate engine with timing chain(s) removed. Damage to valve/piston may result.

Remove retaining bolts, left chain tensioner, left tensioner arm and left chain guide. See Fig. 13 . Remove left timing chain and crankshaft sprocket. Note direction of sprocket for installation reference. If necessary for clearance, remove retaining bolt, washer, camshaft sprocket and spacer.

Inspection

CAUTION: If components are replaced due to damage, ensure crankshaft is rotated so pistons are below deck surface (crankshaft keyway at 90 degrees) to prevent contact with valves. See STEP 1 in illustration. See Fig. 8 . Ensure camshaft positioner is installed on camshaft(s) before installing timing chain(s).

Inspect components for damage. Inspect friction surfaces on tensioner arms and chain guides for wear. Replace components if necessary. If tensioner arms or guides are worn or damaged, remove and clean oil pan. Also, replace oil pump screen cover and tube.

Installation

1. Install spacers, camshaft sprockets and retaining bolts. Ensure components are installed into original locations. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

2. Install camshaft positioner onto flat areas of camshaft if not previously installed. See Fig. 9 .

3.

CAUTION: Install crankshaft sprocket halves with hubs facing each other. See Fig. 14 .

Install crankshaft sprocket for left timing chain. If copper links are not visible on timing chain, fold timing chain in half and mark each end link for timing purposes. See Fig. 14 . These links will be referred to as copper links when installing.

4. Ensure No. 1 piston is at TDC. This positions crankshaft keyway 45 degrees from vertical position. See Helpmelearn Repair Manuals Wednesday, November 08, 2006 7:35:52 PM

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5.

6.

7.

8.

9.

10.

11.

12.

Fig. 8 . Crankshaft keyway will point toward camshaft.

Install left timing chain on camshaft and crankshaft sprockets so copper link aligns with timing mark on sprockets. See Fig. 12 . Install crankshaft sprocket for right timing chain. Ensure sprocket is properly installed.

Install right timing chain onto camshaft and crankshaft sprockets so copper link aligns with timing mark on sprockets. Install crankshaft positioner, to prevent crankshaft movement. Lubricate tensioner arms with engine oil. Install tensioner arms. Install chain guides.

Chain tensioners must be bled down so tensioner plunger is compressed into housing before installing.

Place chain tensioner into soft-jaw vise. Using small pick, hold ratchet lock mechanism away from ratchet stem. See Fig. 15 . Slowly close vise to depress tensioner plunger.

When tensioner plunger is compressed into housing, continue to hold ratchet lock mechanism and install lock pin into hole on tensioner housing. Ensure ratchet stem is even with tensioner housing before installing lock pin. See Fig. 15 .

Using "C" clamp or suitable tool, remove all slack from timing chain by applying pressure to tensioner arm. While holding pressure on arm, install both chain tensioners and retaining bolts onto cylinder block.

Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Remove lock pins from both chain tensioners. Ensure all timing marks align. See Fig. 12 . To check accuracy of valve timing, remove No. 1 spark plug. Using a dial indicator, check for maximum intake valve lift. Maximum intake valve lift should occur at 114 degrees after TDC. To install remaining components, reverse removal procedure. Before installing valve cover, apply silicone sealant at front cover-to-cylinder block areas.

When installing fuel lines, fit NEW fuel resistant "O" rings (Brown) on fuel lines. Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace garter spring (if necessary).

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Fig. 12: Identifying Timing Marks Courtesy of FORD MOTOR CO.

Fig. 13: Exploded View Of Timing Chain & Components Courtesy of FORD MOTOR CO. Helpmelearn Repair Manuals Wednesday, November 08, 2006 7:35:53 PM

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Fig. 14: Identifying Crankshaft Sprocket & Timing Chain Timing Marks Courtesy of FORD MOTOR CO.

Fig. 15: Compressing Timing Chain Tensioner Plunger Courtesy of FORD MOTOR CO. CAMSHAFT FOLLOWER & LASH ADJUSTER Removal

1. Remove valve covers. See VALVE COVERS . Rotate crankshaft until piston in cylinder to be serviced Helpmelearn Repair Manuals Wednesday, November 08, 2006 7:35:53 PM

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is at bottom of its stroke, and camshaft lobe is at base circle.

2. Install valve spring spacer between valve spring coils to prevent valve stem oil seal damage. Using valve spring compressor, compress valve spring. Remove camshaft follower and lash adjuster.

Inspection

Inspect components for damage. Measure lash adjuster O.D. and oil clearance. Replace components if damaged or measurements are not within specification. See VALVE LASH ADJUSTER table under ENGINE SPECIFICATIONS. Installation

CAUTION: Before installing, ensure lash adjuster is full of oil and plunger does not have more than .059" (1.49 mm) travel. Ensure piston is at bottom of stroke and camshaft lobe is on base circle.

1. To install, reverse removal procedure. Coat components with engine oil before installing. Before installing valve cover, apply silicone sealant at front cover-to-cylinder block areas.

2. When installing fuel lines, fit NEW fuel resistant "O" rings (Brown) on fuel lines. Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace garter spring (if necessary).

CAMSHAFT Removal

Remove camshaft followers and lash adjusters. See CAMSHAFT FOLLOWER & LASH ADJUSTER .

Remove timing chains. See TIMING CHAINS . Remove camshaft cap bolts in reverse order of tightening sequence. See Fig. 16 . On Romeo engines, tap camshaft caps in designated areas to remove camshaft caps. See Fig. 17 . On both engines. remove camshaft caps and camshaft.

Inspection

Measure camshaft bore I.D. and journal O.D. to determine oil clearance. Measure lobe lift. Replace camshaft if measurements are not within specification. See CAMSHAFT table under ENGINE SPECIFICATIONS. Installation

1.

CAUTION: Ensure proper procedure is used when installing timing chains to prevent engine damage. See TIMING CHAINS .

Coat components with engine oil, and install components. Install all bolts for both camshaft caps, and tighten them finger tight. Tighten bolts to 72-106 INCH lbs. (8-12 N.m) in sequence. See Fig. 16 .

Loosen all bolts 2 turns. Retighten bolts to 72-106 INCH lbs. (8-12 N.m) in sequence. Repeat procedure for each camshaft.

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2. Ensure camshaft end play is within specification. See CAMSHAFT table under ENGINE SPECIFICATIONS. To install remaining components, reverse removal procedure. Tighten all bolts to specification. See TORQUE SPECIFICATIONS .

Fig. 16: Camshaft Cap Bolt Tightening Sequence Courtesy of FORD MOTOR CO.

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Fig. 17: Removing Camshaft Caps (Romeo Engine) Courtesy of FORD MOTOR CO. CRANKSHAFT REAR OIL SEAL Removal

1. Remove transmission. See TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. Remove oil pan. See OIL PAN . Remove flywheel. Remove rear oil seal retainer.

2. Using rear crankshaft slinger remover and slide hammer, remove oil slinger. Using rear crankshaft seal remover, remove oil seal.

Installation

Clean and inspect all mating surface. Install rear seal retainer. See Fig. 18 . Using rear crankshaft seal replacer and rear crankshaft seal adapter, install rear seal. With rear crankshaft adapter still installed, use rear crankshaft slinger replacer and seal replacer to install seal slinger. To complete installation, reverse removal procedure.

Tighten bolts to specifications. See TORQUE SPECIFICATIONS .

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Fig. 18: Seal Retainer Bolt Tightening Sequence Courtesy of FORD MOTOR CO. WATER PUMP Removal & Installation

1. Drain cooling system. Remove cooling fan and shroud. Release belt tensioner, and remove accessory drive belt. Remove water pump pulley. Remove retaining bolts, water pump and "O" ring.

2. To install, reverse removal procedure. Lubricate "O" ring with coolant before installing. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Fill cooling system.

OIL PAN WARNING: Ensure air suspension system is shut off prior to hoisting, jacking or towing an air suspension vehicle. Air suspension switch is located behind right kick panel. Failure to do so can result in inflation or deflation of air springs, which may cause vehicle to shift during servicing.

Removal (E150)

1. Disconnect negative battery cable(s). Remove engine cover. Remove air cleaner and outlet tube assembly.

Remove cooling fan and fan shroud. Remove oil indicator tube. Remove throttle body. Raise and support vehicle.

2. Drain engine oil. Drain cooling system. Remove radiator hose. Remove motor mount-to-subframe nuts.

Remove flywheel inspection plate. Raise engine and position blocks between motor mounts and Helpmelearn Repair Manuals Wednesday, November 08, 2006 7:35:53 PM

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subframe. Remove oil pan retaining bolts in reverse sequence. See Fig. 19 . Remove oil pan.

Removal (2WD Expedition & F150 Pickup)

1. Disconnect negative battery cable. Drain cooling system. Remove radiator air deflector. Remove air cleaner. Disconnect throttle cable and throttle position sensor electrical connector. Disconnect vacuum connections.

2. Disconnect EGR valve. Remove throttle body adapter. Remove fan shroud. Raise and support vehicle.

Drain engine oil. Remove engine mount through-bolts.

3. Raise engine. Remove oil pan retaining bolts in reverse sequence. See Fig. 19 . Remove oil pan.

Removal (4WD Expedition & F150 Pickup)

Raise and support vehicle. Remove front axle housing. See appropriate DIFFERENTIALS article in DRIVE AXLES. Drain engine oil. Remove oil pan retaining bolts in reverse of tightening sequence. See Fig. 19 .

Remove oil pan.

Installation (All Models)

1. To install, reverse removal procedure. Apply silicone sealant on front cover and seal retainer-to-cylinder block areas before installing gasket and oil pan. Tighten all bolts to specification in sequence. See Fig. 19 . See TORQUE SPECIFICATIONS .

2. When installing fuel lines, fit NEW fuel resistant "O" rings (Brown) on fuel lines. Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace garter spring (if necessary).

3. Adjust all control cables and fluid levels. Refill cooling system. Evacuate and recharge A/C system.

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