Material — Part 3 Ford Expedition II

Scheme 684

Scheme 685

Scheme 686

Scheme 687

1. If equipped, turn the air suspension switch off.
2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-209881) .
3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-209935) .
4. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-209907) .
5. Partially drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-209901) .
6. Remove the upper air deflector. Remove the pin-type retainers. Remove the upper air deflector.
7. Disconnect the throttle body cam. Disconnect the accelerator cable. Disconnect the speed control actuator cable. Remove the accelerator return spring.
8. Position the heated positive crankcase ventilation (PCV) hose harness aside. Disconnect the PCV hose from the throttle body adapter. Disconnect the heated throttle body outlet hose from the throttle body adapter. Disconnect the PCV hose from the intake manifold. Remove the PCV valve and position the harness aside.
9. Disconnect the heated throttle body inlet hose from the throttle body adapter.
10. Disconnect the evaporative emission canister purge valve hose.
11. Disconnect the main vacuum harness from the throttle body adapter.
12. Remove the idle air control (IAC) valve fresh air tube.
13. Disconnect the IAC electrical connector.
14. Disconnect the EGR valve vacuum hose.
15. Disconnect the throttle position (TP) sensor electrical connector, and the exhaust gas recirculation (EGR) vacuum regulator solenoid electrical and vacuum connectors.
16. Disconnect the differential pressure feedback EGR system electrical connector.
17. Remove the bolt and disconnect the brake booster vacuum tube. Position the bracket and tube aside.
18. Remove the exhaust manifold to EGR valve tube. Disconnect the upper fitting. Disconnect the two differential pressure feedback EGR system hoses. Disconnect the lower fitting and remove the tube.
19. Remove the differential pressure feedback EGR system bracket bolt.
20. Remove the four bolts and remove the throttle body adapter. Discard the throttle body adapter gasket.
21. Rotate the belt tensioner clockwise and detach the drive belt from the generator pulley.
22. Disconnect the generator upper mounting bracket. Disconnect the harness routing clip. Remove the two bolts.
23. Remove the generator lower mounting bolts and position the generator aside.
24. Install the special tool.
25. Remove the fan shroud mounting bolts.
26. Remove the front fender splash shield.
27. If equipped, remove the fasteners and the engine skid shield.
28. If equipped, remove the six bolts and the transmission skid shield.
29. Remove the dual converter Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-209916) .
30. Remove the LH engine mount bolt.
31. Remove the RH engine mount nut.
32. Loosen the rear transmission mount nuts.
33. Index-mark the driveshaft flange yoke and the pinion flange.
34. Remove the four bolts.
35. Using a suitable tool as shown, disconnect the driveshaft flange yoke from the pinion flange.
36. Wire the driveshaft to the frame crossmember to support it at the same height as when it was installed.
37. Install the special tool and raise the engine.
38. Remove the eight nuts, the exhaust manifold and the gasket. Discard the exhaust manifold gasket.
39. Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-209898) .

Scheme 688

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Scheme 713

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Scheme 716

1. Position the exhaust manifold gasket and the exhaust manifold. Loosely install the nuts.
2. Tighten the nuts in the sequence shown.
3. Lower the engine and remove the special tool.
4. Remove the driveshaft support wire.
5. Align the index marks and install the driveshaft flange yoke to the pinion flange. Tighten the bolts in the sequence shown.
6. Tighten the rear transmission mount nuts.
7. Install the RH engine mount nut.
8. Install the LH engine mount bolt.
9. Install the dual converter Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-209916) .
10. If equipped, position the transmission skid shield and install the six bolts.
11. If equipped, position the engine skid shield and install the fasteners.
12. Install the front fender splash shield.
13. Position the fan shroud and install the mounting bolts.
14. Position the generator and install the lower mounting bolts.
15. Install the generator upper mounting bracket bolts and harness routing clip.
16. Rotate the belt tensioner clockwise and install the drive belt. Refer to the decal on the radiator upper air deflector for belt routing.
17. Install a new intake manifold-to-throttle body adapter gasket.
18. Install the throttle body adapter. Install a new throttle body adapter gasket. Position the throttle body adapter and install the bolts in two stages: Stage 1: Tighten to 9 Nm (80 lb-in). Stage 2: Tighten an additional 90 degrees.
19. Install the differential pressure feedback EGR system bracket bolt.
20. Install the exhaust manifold to EGR valve tube. Position the tube and hand-tighten the fittings. Tighten the upper fitting. Tighten the lower fitting. Connect the two differential pressure feedback EGR system hoses.
21. Connect the brake booster vacuum tube and position the bracket. Install the bolt.
22. Connect the differential pressure feedback EGR system electrical connector.
23. Connect the TP sensor electrical connector, and the EGR vacuum regulator solenoid electrical and vacuum connectors.
24. Connect the EGR valve vacuum hose.
25. Connect the IAC electrical connector.
26. Install the IAC fresh air tube.
27. Connect the main vacuum harness.
28. Connect the evaporative emission canister purge valve hose.
29. Connect the heated throttle body inlet hose to the throttle body adapter.
30. Install the heated PCV hose harness. Install the PCV valve. Connect the PCV hose to the intake manifold. Connect the heated throttle body outlet hose. Connect the PCV hose to the throttle body adapter.
31. Connect the throttle body cam. Connect the accelerator cable. Connect the speed control actuator cable. Install the throttle return spring.
32. Install the upper air deflector. Position the upper air deflector. Install the pin-type retainers.
33. Install the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-209907) .
34. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-209935) .
35. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-209898) .
36. If equipped, turn on the air suspension switch.

Scheme 717

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Scheme 737

Scheme 738

Scheme 739

Scheme 740

Scheme 741

Scheme 742

Scheme 743

Scheme 744

Scheme 745

1. If equipped, turn the air suspension switch off.
2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-209881) .
3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-209935) .
4. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-209907) .
5. Partially drain the engine cooling system. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-209898) .
6. Remove the upper air deflector. Remove the pin-type retainers. Remove the upper air deflector.
7. Remove the three bolts and the appearance cover mounting bracket.
8. Disconnect the throttle body cam. Disconnect the accelerator cable. Disconnect the speed control actuator cable. Remove the accelerator return spring.
9. Disconnect the main vacuum harness.
10. Disconnect the positive crankcase ventilation (PCV) hose.
11. Remove the idle air control (IAC) fresh air hose and disconnect the differential pressure feedback exhaust gas recirculation (EGR) sensor electrical connector.
12. Disconnect the IAC and throttle position (TP) sensor electrical connectors.
13. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose and the evaporative emission canister purge valve hose and position them aside.
14. Disconnect the differential pressure feedback EGR sensor vacuum hoses from the EGR tube.
15. Remove the nut and disconnect the brake booster vacuum tube. Position the bracket and tube aside.
16. Disconnect the exhaust manifold to EGR valve tube fittings and remove the tube.
17. Remove the four bolts and move the throttle body adapter forward slightly.
18. Disconnect the heated throttle body hoses and remove the throttle body adapter and PCV hose from the vehicle. Discard the throttle body adapter-to-intake manifold gasket. Inspect the throttle body and adapter for damage.
19. Rotate the belt tensioner clockwise and detach the drive belt from the generator pulley.
20. Disconnect the harness routing clip.
21. Remove the two bolts.
22. Remove the generator lower mounting bolts and position the generator aside.
23. Install the special tool.
24. Remove the fan shroud mounting bolts.
25. Remove the front fender splash shield.
26. If equipped, remove the fasteners and the engine skid shield.
27. If equipped, remove the six bolts and the transmission skid shield.
28. Remove the dual converter Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-209916) .
29. Remove the LH engine mount bolt.
30. Remove the RH engine mount nut.
31. Loosen the rear transmission mount nuts.
32. Index-mark the driveshaft flange yoke and the pinion flange.
33. Remove the four bolts.
34. Using a suitable tool as shown, disconnect the driveshaft flange yoke from the pinion flange.
35. Wire the driveshaft to the frame crossmember to support it at the same height as when it was installed.
36. Install the special tool and raise the engine.
37. Remove the bolts and the heat shield.
38. Remove the eight nuts, the exhaust manifold and the gaskets. Discard the exhaust manifold gaskets.
39. Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-209898) .

Scheme 746

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