Removal & Installation (SVT)

1. Release the fuel system pressure. See FUEL PRESSURE RELEASE under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES article.
2. Disconnect the A/C pressure switch harness connector. See Fig 1.
3. Raise and support vehicle. Remove the right front wheel and tire.
4. Remove the fender splash shield. See Fig 2.
5. Evacuate the A/C system. See REFRIGERANT SYSTEM RECOVERY under FORD MOTOR CO. under RECOVERY/EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in AIR CONDITIONING & HEATING.
6. Remove the radiator.
CAUTION: Over bending of the flexible pipe may cause damage resulting in failure.
7. Support the flexible pipe with a support wrap or suitable splint. See Fig 3.
8. Disconnect the exhaust flexible pipe from the muffler and tailpipe assembly. Discard the gasket and nuts. See Fig 4.
9. Disconnect the engine rear support insulator from the support insulator bracket. See Fig 5.
10. Lower the vehicle.
11. Remove the coolant expansion tank bolt. Detach the coolant expansion tank from the wheelhouse assembly and position it to one side. See Fig 6.
12. Disconnect the power steering fluid reservoir from the wheelhouse assembly and position it to one side. See Fig 7.
13. Disconnect the Powertrain Control Module (PCM) harness connector. See Fig 8.
14. Disconnect the PCM electrical connector bracket. See Fig 9.
15. Disconnect the headlight wiring harness ground cable. See Fig 10.
16. Using a suitable hoist support the engine. See Fig 11.
17. Detach the engine front mount bracket from the side member. See Fig 12.
CAUTION: Ensure excessive force is not placed on the remaining engine mount when moving the engine forward.
18. Move the engine front mount towards the front of the vehicle to its maximum deflection. See Fig 13.
19. Detach the PCM wiring harness from the bulkhead. See Fig 14.
20. Detach the brake tubes from the bulkhead. See Fig 15.
21. Remove the fuel line. See Fig 16.
CAUTION: Cap the refrigerant line and the evaporator to prevent dirt ingress.
22. Using the special tool disconnect the accumulator refrigerant line from the evaporator. See Fig 17. Discard the "O" ring seal.
23. Using the special tool disconnect the condenser refrigerant line from the evaporator. See Fig 18. Discard the "O" ring seal.
24. Detach the refrigerant lines from the wheelhouse assembly and remove the refrigerant line retaining bracket. See Fig 19.
25. Remove the refrigerant lines from the engine compartment. Pulling the refrigerant line through the fender.
26. Remove the master cylinder. See MASTER CYLINDER .
27. Disconnect the brake pedal switches from the brake pedal bracket. Unlock the switches. Disconnect the switches. See Figure.
28. Disconnect the brake booster actuating rod from the brake pedal. Press the brake pedal. Press the clip. Remove the brake booster actuating rod pin. See Figure.
29. Remove the brake booster retaining nuts. See Figure.
30. Disconnect the brake booster solenoid valve harness connector. See Fig 20.
31. Remove the brake booster.
32. To install, reverse removal procedures. Install NEW refrigerant "O" ring seals coated with refrigerant oil. Coat flexible pipe studs with anti-seize grease and install NEW exhaust gaskets and nuts. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS .