96 gt motor pull!!!!

Discussion in '96-04 - 2V Specific' started by firstonraceday, Apr 18, 2007.

  1. firstonraceday

    firstonraceday Active Member

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    I was wondering if there was a write up anywhere to guide me through this???? also doen anyone know how many bolts there are total on the tranny bellhousing???
     
  2. gt96stang

    gt96stang Well-Known Member

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  3. ripper

    ripper Well-Known Member

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    Thats a nice write up. But if you have a lift availabe the best way to remove the engine is to take it out the bottom by removing the k member. Its 100 times easier and you dont have to remove alot of stuff before you drop it.
     
  4. firstonraceday

    firstonraceday Active Member

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    ^^^ yea I was thinking about doing that but im not sure i have enough space in my garage...
     
  5. ripper

    ripper Well-Known Member

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    You have to be able to raise the car about 5 feet. You drop the motor on a dolly and disonnect the engine hoist WALA. lol The higher you can get the car the easier on your back it is.


    ps change your motor mounts and water pump before installing new motor. If you have shorties you can install the motor with them on. Longtubes wait till trani is back in. ( if you got longtubes spring for a new starter too)
     
  6. St33da

    St33da Active Member

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    [​IMG]

    REMOVAL

    1. Disconnect battery ground cable (14301).
    2. Remove hood (16612). Refer to Body and Frame.
    3. Remove engine compartment brace from front fender apron (16055) and dash panel.
    4. Drain engine cooling system.
    5. Remove air cleaner outlet tube (9B659). Refer to Powertrain Management.
    6. Recover air conditioning system. Refer to Heating and Air Conditioning.
    7. Remove radiator coolant recovery reservoir (8A080).
    8. Remove cooling fan motor/fan blade (8600) and fan shroud (8146) assembly.
    9. Relieve fuel system pressure and disconnect fuel tubes (9291) from fuel injection supply manifold (9F792). Refer to Powertrain Management.
    10. Disconnect fuel charging wiring 42-pin connector and 8-pin connector and position out of the way.
    11. Disconnect accelerator cable (9A758) and speed control actuator cable (9A825) from throttle body (9E926) and from accelerator cable bracket (9723). Position accelerator cable and speed control actuator cable out of the way.
    12. Disconnect fuel charging wiring (9D930) and front evaporative emission hose from evaporative emission canister purge valve (EVAP canister purge valve)(9C915).
    13. Disconnect positive battery cable from power distribution box and harness (14516).
    14. Disconnect chassis vacuum supply hose from main emission vacuum control connector (9E498).
    15. Disconnect transmission oil cooler tubes from transmission oil cooler.
    16. Remove upper radiator hose (8260).
    17. Disconnect water heater supply and return hoses.
    18. Disconnect air conditioning compressor suction and discharge hoses from A/C compressor (19703) using Spring Lock Coupling Disconnect Tool (3/8 inch) T81P-19623-G1 and (1/2 inch) T81P-19623-G2.
    19. Disconnect engine to frame wire (14324) from dash panel (01610).
    20. Raise and support vehicle.
    21. Drain engine oil.
    22. Remove dual converter Y pipe (TWC) (5F250). Refer to Powertrain Management.
    23. Remove lower radiator hose (8286).
    24. Loosen spring clamps and remove power steering hoses from power steering fluid cooler (3D746).
    25. Disconnect power steering pressure hose (3A719) and power steering return hose (3A713) from the power steering pump (3A674).
    26. Remove starter motor (11002).
    27. Remove transmission. Refer to Transmission and Drivetrain.
    28. Remove LH and RH front engine support insulator through bolts.
    29. Lower vehicle NOTE: Attach Engine Lifting Brackets D91P-6001-A or equivalent using two M-12 x 1.75 x 20 mm bolts.
    30. Install engine lifting bracket from Engine Lifting Brackets D91P-6001-A2 or equivalent on side of LH cylinder head (6049) at front as shown. Install engine lifting bracket from Engine Lifting Brackets D91P-6001-A1 or equivalent on side of RH cylinder head at rear as shown.
    31. Connect Rotunda Floor Crane 014-00071 or equivalent to the lift brackets.
    32. Raise engine from vehicle.
    33. Lower engine to a level, stationary surface.
    34. If equipped with a manual transmission, remove clutch pressure plate (7563) and clutch disc (7550).
    35. Remove flywheel (6375).
    36. Position engine on a work stand.
    37. Remove engine lifting equipment.

    INSTALLATION

    1. Install Engine Lifting Bracket Set D91P-6001-A or equivalent in positions shown.
    2. Connect Rotunda Floor Crane 014-00071 or equivalent to lifting brackets and remove engine from work stand and install flywheel. If equipped, install clutch pressure plate and clutch disc.
    3. Carefully install engine into vehicle.
    4. If equipped with automatic transmission, position transmission oil cooler tube bracket to transmission case to cylinder block bracket stud and install retaining nut. Tighten to 20-30 Nm (15-22 ft. lbs.) .
    5. Raise and support vehicle.
    6. Install LH and RH front engine support insulator through bolts. Tighten through bolts to 20-30 Nm (15-22 ft. lbs.) .
    7. Install transmission.
    8. Install power steering pressure hose and power steering return hose to power steering pump.
    9. Install lower radiator hose.
    10. Connect power steering hoses to power steering oil cooler.
    11. Connect engine to frame wire to dash panel.
    12. Install starter motor.
    13. Install dual converter Y pipe (TWC) .
    14. Lower vehicle.
    15. Remove lift brackets from cylinder heads.
    16. Connect A/C suction and discharge lines to A/C compressor. Refer to Heating and Air Conditioning.
    17. If equipped with an automatic transmission, install transmission oil cooler tubes to transmission fluid cooler (7A095).
    18. Install upper radiator hose to radiator (8005).
    19. Connect heater water supply and return hoses.
    20. Connect body vacuum supply hose to main emission vacuum control connector adapter vacuum port.
    21. Connect positive battery cable to power distribution box and harness.
    22. Connect fuel charging wiring and front evaporative emission hose to evaporative emission canister purge valve.
    23. Connect accelerator cable and speed control actuator cable to the throttle body and accelerator cable bracket. Verify proper operation.
    24. Connect 42-pin and 8-pin fuel charging wiring connectors.
    25. Connect fuel supply and return fuel tubes to the fuel injection supply manifold.
    26. Install cooling fan motor/fan blade and fan shroud assembly.
    27. Install radiator coolant recovery reservoir.
    28. Install air cleaner outlet tube and engine air cleaner (ACL) (9600). Refer to Powertrain Management.
    29. Install engine compartment brace. Tighten retaining bolts to 20-30 Nm (15-22 ft. lbs.) .
    30. Fill power steering system.
    31. Fill crankcase to specified level on oil level dipstick (6750) with clean engine oil meeting Ford specification WSS-M2C153-F.
    32. Connect battery ground cable.
    33. Fill and bleed engine cooling system.
    34. Evacuate and recharge air conditioning system. Refer to Heating and Air Conditioning.
    35. Start engine and check for coolant, oil and fuel leaks. Recheck all fluid levels.
    36. Install hood.
     
  7. ripper

    ripper Well-Known Member

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    Are you repairing this motor and putting it back in? Or getting a new motor?
     
  8. firstonraceday

    firstonraceday Active Member

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    wow thanks man....
     
  9. firstonraceday

    firstonraceday Active Member

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    "building" the one thats in there now romeo blocks are goor for about 500 horse aren't they?
     
  10. 19mustang95

    19mustang95 Legend

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    the block is good for much more than 500
     
  11. firstonraceday

    firstonraceday Active Member

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    good :)
     
  12. St33da

    St33da Active Member

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    no problem... just remember that these instruction were most likely written by an engineer rather than a mechanic, so the wording is not so great. just use some common sense and it shouldnt be so bad. i can post the engine rebuild process for a 01 GT if you would like, to assist you in your PI build.
     
  13. firstonraceday

    firstonraceday Active Member

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    thad be great... im trying to gather as much info as I can on pulling the motor and rebuilding it...this will obviousle be my first time. :noes:
     
  14. AaRoN

    AaRoN King Post Whore

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    i am doing this same thing (mine's a 98). pulling the 98 and installing an 01.
     
  15. Dalamar

    Dalamar Legend Retired Staff SN95 Supporter

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    cool, good luck with the build and assembly.
    the stock block is good to 1000 HP!

    what all are you puting in there?
     
  16. St33da

    St33da Active Member

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    Engine

    [​IMG]

    [​IMG]


    Special Tool(s)

    Assembly

    NOTE: Before assembling the cylinder block, all sealing surfaces must be free from chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.

    1. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.

    2. NOTE: Do not install the upper thrust washer until the crankshaft is installed. Refer to Step 3.
    [​IMG]
    Install the crankshaft onto the upper main bearings.

    3. NOTE: The oil groove on the thrust washer must face toward the rear of the engine (against the crankshaft surface).
    [​IMG]
    Push the crankshaft rearward and install the crankshaft upper thrust washer at the rear of the No. 5 main boss.

    4. NOTE: Rotate the jackscrews into the bearing caps enough to provide clearance to the cylinder block prior to installing the bearing caps. Install the lower main bearings into the main bearing caps and lubricate them with clean engine oil.
    [​IMG]

    5. Install the rear main bearing cap.
    [​IMG]

    6. Install the remaining main bearing caps on the cylinder block and tap into place using a plastic or dead-blow hammer.
    [​IMG]

    7. Install the vertical main bearing cap fasteners and tighten in the sequence shown.
    o Tighten to 40 Nm (30 ft. lbs.).
    o Tighten an additional 85 - 95 degrees.
    [​IMG]

    8. Tighten the jackscrews against the cylinder block in the sequence shown.
    o Tighten to 5 Nm (44 ft. lbs.).
    o Tighten to 10 Nm (89 inch lbs.).
    [​IMG]

    9. Install the side bolts and tighten them in the sequence shown.

    10. Check the crankshaft end play.

    11. CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod. NOTE:
    o Make sure the crankshaft is facing forward.
    o Lubricate the piston rings, cylinder walls and connecting rod bearings with clean engine oil.
    [​IMG]

    Using the special tool, push the pistons through the top of the cylinder block.
    12. CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod. NOTE: Make sure the crankshaft is at TDC.
    [​IMG]

    Using the special tool, install the connecting rod assemblies.
    13. NOTE: These bolts are torque-to-yield. Install new bolts each time they are serviced.
    [​IMG]

    Install the connecting rod bearing caps and bolts and tighten in three stages.

    * Stage 1: Tighten to 25 Nm (18 ft. lbs.).
    * Stage 2: Tighten to 40 Nm (30 ft. lbs.).
    * Stage 3: Tighten an additional 90 degrees.

    14. Check the connecting rod bearing clearance.
    [​IMG]

    15. Install the oil pump and a new gasket. Tighten the bolts in the sequence shown.

    16. NOTE: Install a new O-ring if necessary.
    [​IMG]
    Install the oil pump screen cover and tube.
    [​IMG]

    17. Install the oil pan and gasket and loosely install the bolts.
    [​IMG]


    18. Tighten the bolts in the sequence shown.

    o Tighten to 20 Nm (15 ft. lbs.).
    o Rotate an additional 60 degrees.
    [​IMG]

    19. Install the drain plug.
    [​IMG]


    20. Install the cylinder head gaskets.

    21. NOTE: The LH is shown the RH is similar.
    [​IMG]
    Tighten the bolts in six stages in the sequence shown.

    * Stage 1: Tighten to 40 Nm (30 ft. lbs.).
    * Stage 2: Tighten an additional 90 degrees.
    * Stage 3: Loosen the bolts a minimum of one full turn.
    * Stage 4: Tighten to 40 Nm (30 ft. lbs.).
    * Stage 5: Tighten an additional 90 degrees.
    * Stage 6: Tighten an additional 90 degrees.

    22. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
    [​IMG]
    Compress the tensioner plunger, using a vise.
    [​IMG]

    23. Install a retaining clip on the tensioner to hold the plunger in during installation.

    24. Remove the tensioner from the vise.
    [​IMG]

    25. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
    [​IMG]

    26. Install the timing chain guides.

    1. Position LH timing chain guide.
    2. Install and tighten the bolts.
    3. Position the RH timing chain guide.
    4. Install and tighten the RH bolts.
    [​IMG]

    27. Install the crankshaft sprocket, making sure the flange faces forward.
    [​IMG]

    28. Install the timing chains.

    o Install the LH (inner) timing chain on the crankshaft sprocket, aligning the copper link with the dot on the crankshaft sprocket.
    o Install the LH timing chain on the camshaft sprocket aligning the copper link with the dot on the camshaft sprocket.
    o Install the RH (outer) timing chain on the crankshaft sprocket, aligning the copper link with the dot on the crankshaft sprocket.
    o Install the RH timing chain on the camshaft sprocket aligning the copper link with the dot on the camshaft sprocket.
    [​IMG]

    29. Make sure that the (A) copper marks on the timing chains are lined up with the corresponding dots on the crankshaft sprockets and camshaft sprockets.
    [​IMG]

    30. Make sure that the (A) camshaft sprocket keyway is 90 degrees from the (B) valve cover mounting surface.

    31. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole, for identification.
    [​IMG]
    Position the LH and RH timing chain tensioner arm on the dowel pins.
    [​IMG]

    32. Position the RH timing chain tensioner and install the timing bolts.
    [​IMG]

    33. Position the LH timing chain tensioner and install the bolts.
    [​IMG]

    34. Remove the retaining clips from the RH and LH timing chain tensioners.
    [​IMG]

    35. Position the crankshaft sensor ring on the crankshaft.

    36. NOTE: The front cover must be installed within four minutes of applying sealer.
    [​IMG]
    Apply silicone gasket and sealant in the locations shown.
    [​IMG]
    [​IMG]

    37. Install the engine front cover.
    [​IMG]

    38. Tighten the four oil pan bolts in the sequence shown.

    o Stage 1: Tighten to 2 Nm (18 inch lbs.).
    o Stage 2: Tighten to 20 Nm (15 ft. lbs.).
    o Stage 3: Tighten an additional 60 degrees.
    [​IMG]

    39. Install the belt idler pulleys.
    [​IMG]

    40. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.
    [​IMG]

    41. Using the special tool, install the front oil seal.
    [​IMG]

    42. Install the water pump pulley and bolts.

    43. NOTE: The crankshaft pulley must be installed within four minutes of applying the sealant.
    [​IMG]
    Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
    [​IMG]

    44. Using the special tool, install the crankshaft pulley.
    [​IMG]

    45. Install the washer and the bolt.Tighten the bolt in four stages.

    o Stage 1: Tighten to 90 Nm (66 ft. lbs.).
    o Stage 2: Loosen one full turn.
    o Stage 3: Tighten to 50 Nm (37 ft. lbs.).
    o Stage 4: Tighten an additional 90 degrees.

    46. Install the oil filter adapter.
    [​IMG]

    47. NOTE: The RH side is shown, the LH side is similar.
    [​IMG]
    Apply silicone gasket and sealant in the locations shown.

    48. NOTE: The RH valve cover is shown, the LH is similar.
    [​IMG]
    Install the valve covers.

    49. Install a new O-ring.
    [​IMG]

    50. Install the tube.
    [​IMG]

    51. NOTE: The RH exhaust manifold is shown, the LH is similar. Tighten the bolts in sequence shown.
    [​IMG]
    Install the exhaust manifolds.

    52. Connect the lower end of the EGR tube to the LH exhaust manifold.
    [​IMG]

    53. Install the intake manifold and gaskets. Tighten the bolts in the sequence shown.
    [​IMG]
    54. Install the water thermostat and O-ring.

    o Install a new O-ring as necessary.
    [​IMG]

    55. Install the water outlet adapter.
    [​IMG]

    56. Connect the heater hose.
    [​IMG]

    57. Install the generator.
    [​IMG]

    58. Install the upper generator support bracket.
    [​IMG]

    59. Install the accessory drive belt.
    [​IMG]

    60. Install the radio interference capacitors.

    61. Install the ignition coils and bolts.
    [​IMG]

    62. Install the fuel injection supply manifold and fuel injectors as an assembly.
    [​IMG]

    63. Install the four intake manifold studs.
    [​IMG]

    64. Position the throttle body and install the bolts, tightening in the sequence shown.
    [​IMG]

    65. Install the PCV valve and hose as an assembly.
    [​IMG]

    66. Connect the PCV hose to the base of the throttle body.
    [​IMG]

    67. Connect the EGR tube to the EGR valve
    [​IMG]


    68. Install the EGR vacuum regulator solenoid.

    1. Install the vacuum lines.
    2. Install the electrical connector.
    3. Install the bolts.
    [​IMG]

    69. Position the bracket, tighten the engine mount bolt and nut.
    [​IMG]

    70. Connect the evaporative emissions return line.
    [​IMG]

    71. Install the breather tube.
    [​IMG]

    72. Install the engine control sensor wiring.
    [​IMG]
    [​IMG]
    [​IMG]
     
  17. firstonraceday

    firstonraceday Active Member

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    HOLY SH*T WOW :banana: :banana: :banana: thanks for all the info man..... where the hell do you get all this stuff? :drunk:
     
  18. St33da

    St33da Active Member

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    im a mechanic.... i get it from the program we use at the dealership
     
  19. firstonraceday

    firstonraceday Active Member

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    MMR mod 900 shortblock , FRPP PI Heads , Pi intake , and some custom cams.. are in the future
     
  20. 97gtconv.

    97gtconv. Member

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    looks like u took that info right out of Workshop Manual. it comes in very handy!