Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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1. Drain the cooling system. Refer to Section 03-03 for the procedure. 2. Disconnect the battery ground cable (14301) . 3. Remove the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05 for the removal procedures. 4. Raise and support the vehicle. 5. Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley (8509) while removing the four water pump pulley bolts. 6. Remove the water pump pulley from the water pump (8501) . 7. Remove the crankshaft pulley (6312) . Refer to the procedure in this section 8. Remove the five lower engine front cover bolts and the lower engine front cover (6019) . 9. NOTE: Make a note of the location of the one water pump stud/bolt for ease of installation. Remove the six water pump bolts. 10. Remove the water pump . Installation 1. NOTE: Ensure the mating surfaces between the water pump and the cylinder block (6010) are cleaned of any sealant material. Install a continuous 2.0-3.0mm (0.079-0.118 inch) wide bead of Gasket Maker E2AZ-19562-B or equivalent meeting Ford specification WSK-M2G348-A5, on the water pump and position the water pump on the cylinder block . 2. NOTE: Refer to the note made during removal for the location of the stud/bolt. Install the six water pump bolts. Tighten the water pump bolts to 16-21 Nm (12-15 lb-ft). 3. Position the water pump pulley on the water pump and install the four water pump pulley bolts. 4. Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley , and tighten the four water pump pulley bolts to 16-21 Nm (12-15 lb-ft). 5. Install the lower engine front cover and the five lower engine front cover bolts. Tighten the five lower engine front cover bolts to 3-5 Nm (27-44 lb-in). 6. Install the crankshaft pulley . Refer to the procedure in this section. 7. Lower the vehicle. 8. Install and adjust the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05 for the installation and adjustment procedures. 9. Connect the battery ground cable . 10. Fill the cooling system. Refer to Section 03-03 for the procedure. 11. Start the engine (6007) and check for leaks.

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1. NOTE: The location of engine mountings and engine support insulators are described looking from the transaxle to the engine. Remove the front wheels. For additional information, refer to Section 204-04. 2. Remove the battery. For additional information, refer to Section 414-01. 3. Remove the hood. 4. Remove the bolts and the water pump pulley cover. 1. Detach the coolant hose from the clip. 2. Remove the bolts. 3. Remove the cover. 5. Remove the air cleaner (ACL). For additional information, refer to Section 303-12B. 6. Drain the cooling system. For additional information, refer to Section 303-03. 7. Disconnect the accelerator and speed control cables. 1. Detach the cables from the bracket. 2. Disconnect the accelerator and speed control cables. 8. Remove the selector cable. 1. Remove the bolts. 2. Disconnect the cable. 9. Disconnect the bulkhead electrical connectors. 1. Disconnect the electrical connector. 2. Remove the bolt and disconnect the electrical connector. 10. Detach the central junction box (CJB) and position it to one side. 11. Disconnect the cables. 1. Battery cables. 2. Electrical connector. 3. Ground cable. 12. Disconnect the fan motor electrical connectors. 13. Remove the battery bracket bolts and remove the two ground cables. 14. Remove the battery bracket. 15. Disconnect the fuel line. For additional information, refer to Section 310-00. 16. Disconnect the heater hoses. 17. Disconnect the coolant hoses from the radiator and from the coolant passage.

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1. Remove the upper intake manifold. For additional information, refer to Upper Intake Manifold in this section. 2. Disconnect the fuel line spring lock couplings. For additional information, refer to Section 310-00. 3. Disconnect the fuel pressure sensor. 1. Disconnect the fuel pressure sensor electrical connector. 2. Disconnect the fuel pressure vacuum line. 4. Disconnect the fuel injector electrical connectors and position the wiring harness to one side. 5. CAUTION: Do not loosen or bend the intake manifold runner control (IMRC) cable bracket. The bracket alignment is critical and damage to the IMRC actuator may occur. Disconnect the IMRC actuator cable from the stud and bracket. 6. NOTE: Remove the bolts in the indicated sequence. Remove the lower intake manifold and discard the gaskets. Installation 1. NOTE: Use new lower intake manifold gaskets. NOTE: Tighten the bolts in the indicated sequence. Install the lower intake manifold. Install the gaskets with the locating holes facing downwards. Position the gaskets in the position holes.

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1. Relieve the fuel pressure. Refer to Section 10-01 for the procedure. 2. Disconnect the battery ground cable (14301). 3. Drain the cooling system. Refer to Section 03-03 for the procedure. 4. Remove the engine air cleaner intake tube (9A624) and engine intake air resonator (9F763). Refer to Section 03-12 for the removal procedure. 5. Disconnect the two throttle position (TP) sensor electrical connectors. 6. Slide the TP sensor electrical wiring out of the bracket. 7. Remove the coolant hose from the throttle body (9E926). 8. Disconnect the exhaust gas recirculation (EGR) vacuum regulator solenoid electrical connector. 9. Remove the evaporative emission (EVAP) canister vacuum hose. 10. Disconnect the EVAP canister-to-throttle body hose from the throttle body. 11. Remove the fuel pressure regulator-to-upper intake manifold vacuum hose from the upper intake manifold (9424). 12. Disconnect the No. 1, 3, and 5 cylinder distributor to spark plug wires (12286) from the spark plugs (12405), then remove the spark plug wire boots from in between the upper intake manifold runners. 13. Remove the two spark plug wire bracket bolts and spark plug wire brackets from the upper intake manifold. 14. Remove the distributor dust cover. 15. NOTE: The distributor cap screws are not removable from the distributor cap (12106). Loosen the three distributor cap screws. 16. Remove the distributor cap from the distributor (12127). Position the distributor cap and distributor to spark plug wires aside to gain access to the main engine wiring harness. 17. Disconnect the rear heater valve vacuum hose from the right side of the upper intake manifold, if equipped.

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1. Disconnect battery ground cable (14301) if equipped with liftgate lamps. 2. Remove the two cover caps from the liftgate assist handle. 3. Remove the two liftgate assist handle screws and the liftgate assist handle. 4. If equipped, remove the liftgate lamps and housings. Refer to Section 17-02. 5. If equipped, pull out the plastic lock pins on each side of the liftgate glass latch cover and remove the liftgate glass latch cover. 6. Pull from the top center (nearest liftgate glass) of the liftgate door trim panel (46404) to remove. Installation To install, reverse the removal procedure. Tighten the liftgate pull handle screws to 3 Nm (26 lb-in).