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

download
1. Drain engine cooling system. Refer to Section 03-03. 2. Remove upper radiator sight shield (8C291). 3. Disconnect radiator overflow hose (8075) from radiator (8005). Remove bolts retaining coolant recovery reservoir (8A080) and bracket to radiator support. Disconnect coolant recovery reservoir from lower locator and remove coolant recovery reservoir. 4. Remove cooling fan motor, fan blade (8600) and fan shroud (8146) assembly as described in Section 03-03. 5. Rotate drive belt tensioner (6B209) . Remove drive belt (8620) . Refer to Section 03-05. 6. Remove retaining bolts and water pump pulley (8509) . 7. Remove power steering pump pulley (3A733) and remove water pump-to-power steering pump brace. 8. Remove bolt and nuts retaining ignition coil (12029) and bracket. Position out of the way. 9. Remove heater water outlet tube retaining bolts and heater water outlet tube (18663) from water pump (8501) . 10. Disconnect lower radiator hose (8286) from water pump . 11. CAUTION: If using a prying device to assist in water pump removal, be careful not to damage the mating surfaces. Remove water pump retaining bolts, stud bolts and nuts. Remove water pump . Discard old water pump housing gasket (8507) . Installation 1. NOTE: Lightly oil all bolt and stud threads before installation except those specifying special sealant with SAE 5W-30 Super Premium Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Clean gasket surfaces on water pump and engine front cover (6019) . 2. NOTE: Gasket and Trim Adhesive F3AZ-19B508-B or equivalent meeting Ford specifications ESR-M11P17 and ESE-M2G52-A is recommended to hold the water pump housing gasket in position. Position a new water pump housing gasket on water pump sealing surface. 3. NOTE: The threads of the No. 1 water pump retaining bolt must be coated with Pipe Sealant with Teflon® D8AZ-19554-A or equivalent meeting Ford specifications WSK- M2G350-A2 and ESR-M18P7-A before installing. Position water pump on the engine front cover . Install retaining bolts, stud bolts and nuts. Tighten retaining bolts and studs to 20-30 Nm (15-22 lb-ft). Tighten retaining nuts to 8-12 Nm (71-106 lb-in). 4. Inspect O-ring (replace as necessary) and install heater water outlet tube to water pump . Tighten retaining bolts to 8-12 Nm (71-106 lb-in). 5. Position coil and bracket assembly. Tighten retainers to 25 Nm (18 lb-ft). 6. Install lower radiator hose to water pump . Tighten clamps securely. 7. Install water pump-to-power steering pump brace and install water pump pulley .

download
Engine Front Cover If the engine front cover (6019) is being removed to check timing chain deflection, refer to Timing Chain Deflection Procedure as outlined in Section 03-00. SPECIAL SERVICE TOOL(S) REQUIRED Description Crankshaft Damper Remover Vibration Damper and Seal Replacer T82L-6316-A Vibration Damper Remover Adapter Removal 1. Remove engine (6007) from vehicle. Refer to procedure in this section. 2. Loosen drive belt tensioner (6B209) and drive belt (8620) . 3. Remove water pump pulley retaining bolts and water pump pulley (8509) . 4. Remove retaining bolts and disconnect heater water outlet tube (18663) from water pump (8501) . 5. Disconnect electrical connector at camshaft position sensor. 6. Disconnect electrical connector at crankshaft position sensor (CKP sensor) (6C315) . 7. Remove retaining bolt and disconnect radiator lower hose tube (8291) from water pump . NOTE: If the vibration damper and crankshaft pulley have to be separated, mark the vibration damper and crankshaft pulley so that they may be reassembled in the same relative position. This is important as the vibration damper and crankshaft pulley are initially balanced as a unit. NOTE: If the vibration damper is being replaced, check if the original vibration damper has balance pins installed. If so, new balance pins (6A328 or equivalent) must be installed on the new vibration damper in the same position as the original vibration damper. The crankshaft pulley (new or original) must also be installed in the same relative position as originally installed. 8. Remove crankshaft pulley (6312) and vibration damper assembly using Crankshaft Damper Remover T58P-6316-D and Vibration Damper Remover Adapter T82L-6316-B. 9. Remove four retaining bolts and remove brace from A/C bracket and P/S bracket. 10. Remove oil bypass filter (6714) . Tool Number T58P-6316-D T82L-6316-B CAUTION: The engine front cover cannot be removed without lowering the oil pan (6675) . 11. Remove oil pan . Refer to procedure in this section. CAUTION: Do not overlook the engine front cover retaining bolt located behind the oil pump and filter body (6603) . The engine front cover will break if pried upon and all retaining bolts are not removed. 12. Remove engine front cover retaining bolts. It is not necessary to remove water pump . 13. Remove engine front cover and water pump as an assembly. 14. Remove engine front cover gasket and discard. Water Pump Tightening Sequence Installation NOTE: Lightly oil all bolt and stud bolt threads before installation except those specifying special sealant. 1. Clean gasket surfaces on the engine front cover and cylinder block (6010) . If reusing the engine front cover , replace crankshaft front seal (6700) . Refer to Crankshaft Pulley and/or Damper and/or Crankshaft Front Seal in this section. 2. If a new engine front cover is to be installed: Install oil pump and filter body . Clean water pump gasket surface. Position a new water pump housing gasket (8507) on the engine front cover and install water pump . Install water pump retaining bolts. Tighten to 20-30 Nm (15-22 lb-ft). 3. Lubricate crankshaft front seal with clean engine oil XO-10W30-QSP or -DSP or equivalent meeting Ford specification ESE-M2C153-E. NOTE: Gasket and Trim Adhesive D7AZ-19B508-B or equivalent meeting Ford specification ESE-M2G52-A is recommended to hold the engine front cover gasket (6020) in position while the engine front cover is installed. 4. Position a new engine front cover gasket on the cylinder block and install the engine front cover / water pump assembly using dowels for proper alignment. 5. Install the engine front cover retaining bolts. Tighten to 20-30 Nm (15-22 lb-ft). Install the capscrew (Part No. N804841) nearest the oil bypass filter flange last, and tighten last. Apply Loctite® or equivalent to bolt prior to installation. Refer to illustration under Step 13 of removal procedure. 6. Install oil pan as outlined. 7. Install oil bypass filter . 8. Coat pulley sealing surface with clean engine oil XO-10W30-QSP or -DSP or equivalent meeting Ford specification ESE-M2C153-E. NOTE: When using silicone rubber sealer, assembly must occur within 15 minutes after sealer application. After this time, the sealer may start to setup, and its sealing effectiveness may be reduced. 9. Apply a small amount of Silicone Gasket and Sealant F1AZ-19562-A or equivalent meeting Ford specification WSE-M4G320-A2 to crankshaft keyway. 10. Position crankshaft key (6B316) in the crankshaft keyway.

download
Water Pump Removal 1. Drain the cooling system. Refer to Section 03-03. 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. 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) . NOTE: Make a note of the location of the one water pump bolt with the threads in the bolt head for ease of installation. 9. Remove the six water pump bolts. 10. Remove the water pump . Installation NOTE: Ensure the mating surfaces between the water pump and the cylinder block (6010) are cleaned of any sealant material. 1. 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 . NOTE: Refer to the note made during removal for the location of the bolt with the threads in the bolt head. 2. Install the six water pump bolts. Tighten the water pump bolts to 16-21 Nm (12-15 lb-ft). 3. Install the crankshaft pulley . Refer to the procedure in this section. 4. Position the water pump pulley on the water pump and install the four water pump pulley bolts. 5. 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). 6. 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). 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. 9. Connect the battery ground cable . 10. Fill the cooling system. Refer to Section 03-03. 11. Start the engine (6007) and check for leaks.

download
Removal and Installation 1. Rotate the tensioner clockwise and remove the belt from the power steering pump pulley. 2. Loosen the fitting and disconnect the power steering pressure hose. 3. Disconnect the electrical connector. 4. Disconnect the power steering return line. 5. Using the special tool, remove the power steering pump pulley. 6. Remove the power steering pump mounting bolts and the pump. 7. To install, reverse the removal procedure. 8. NOTE: The pulley must be installed within 0.25 mm (0.010 in) flush with the power steering pump shaft. Using the special tool, install the power steering pump pulley. 9. Using the special tool, install a new seal on the power steering pressure hose fitting. 10. Fill and leak check the system. For additional information, refer to Section 211-00.

download
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.