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

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Crankshaft front seal replacement is recommended whenever the engine front cover (6019) has been removed. 1. Disconnect battery ground cable (14301). Drain crankcase. 2. Drain cooling system. Refer to Section 03-03. 3. Remove drive belts (8620). Refer to Section 03-05. 4. Remove bolts attaching fan shroud (8146) to radiator (8005). 5. Remove fan blade (8600) from fan clutch (8A616) and remove fan shroud. 6. Remove fan clutch and water pump pulley (8509) from water pump (8501). 7. Disconnect upper radiator hose (8260) and lower radiator hose (8286) at engine (6007). Disconnect transmission oil cooler lines at radiator. 8. Remove upper radiator support bracket and remove radiator. 9. Remove generator pivot and attaching bolts. Remove generator (GEN) (10300) from generator mounting bracket (10153) and generator adjusting arm (10145). 10. Remove two bolts attaching generator adjusting arm to water pump and generator mounting bracket and remove generator adjusting arm. 11. Remove air pump pivot and attaching bolts. Remove secondary air injection pump (AIR pump) (9A486) from generator mounting bracket. 12. Remove four bolts attaching generator mounting bracket to cylinder head (6049), cylinder blocks (6010) and water pump, and remove generator mounting bracket. 13. Remove power steering pump pulley (3A733) from power steering pump (3A674). 14. Remove power steering lines from power steering pump. Remove four bolts attaching power steering pump to A/C compressor mounting bracket (2882) and remove power steering pump from A/C compressor mounting bracket. 15. Remove four bolts attaching A/C compressor (19703) to A/C compressor mounting bracket. Remove four bolts and one nut attaching A/C compressor mounting bracket to cylinder head and water pump. Remove A/C compressor mounting bracket from engine. 16. Remove the crankshaft pulley (6312) from the crankshaft vibration damper (6316). 17. Remove bolt and washer attaching crankshaft vibration damper. Remove crankshaft vibration damper using Crankshaft Damper Remover T58P-6316-D or Rotunda Gear and Pulley Puller 014-00293 or equivalent. Remove Woodruff key and crankshaft damper spacer from crankshaft (6303).

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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.

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-00. 2. Remove the hood. 3. Remove the intake manifold. For additional information, refer to Intake Manifold in this section. 4. Remove the accessory drive belt. 5. Discharge and recover the A/C system. For additional information, refer to Section 412-00. 6. Remove the radiator. For additional information, refer to Section 303-03. 7. Remove the powertrain control module (PCM) and the support bracket. For additional information, refer to Section 303-04B. 8. Remove the cowl panel grille. For additional information, refer to Section 501-00. 9. Detach the wiring harness and the windshield washer hose retainers from the cowl panel extension. 11. Disconnect the electrical connector and remove the bolt and the ground strap. 12. Disconnect the heater hose. 13. Disconnect the RH heated oxygen sensor (HO2S) electrical connector and detach the wiring harness retainer. 14. Remove the nut, disconnect the A/C manifold and tube assembly and position aside. 15. Remove the nut and the A/C manifold and tube assembly and support bracket. 16. Remove the nuts, the transmission cooler tube and the power steering pressure tube support brackets. 17. Disconnect the A/C compressor electrical connector. 18. Disconnect the coolant hose. 19. Remove the bolts and position the power steering reservoir assembly aside. 20. Using the special tool, remove the power steering pump pulley. 21. NOTE: Power steering lines shown disconnected for clarity. Remove the bolts and position the power steering pump aside. Detach the wiring harness retainer from the pump assembly.

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Removal All Vehicles 1. Disconnect the battery ground cable. 2. Center the steering wheel. Lock in position, remove the ignition key. 3. Disconnect the steering column shaft from the flexible coupling. Rotate the clamp plate to disengage. 4. CAUTION: When removing the floor seal do not damage the sealing clips. Remove the floor seal from the bulkhead. 1. Release the retaining clips. 2. Disconnect the upper retaining clip. 3. Remove the floor seal. 5. Loosen the left-hand side front wheel nuts. 6. Raise and support the vehicle. For additional information, refer to Section 100-02. 7. Remove the wheel. 8. Remove the radiator splash shield. 9. Disconnect the fluid cooler line. Allow the fluid to drain into a suitable container. 10. Lower the vehicle. Vehicles with 2.0L engine 11. Detach the high-pressure tube support bracket. 12. Detach the high-pressure tube. Disconnect the power steering pressure (PSP) switch electrical connector. Detach the tube support bracket. Cut the three cable ties. 14. Remove the accessory drive belt. For additional information, refer to Section 303-05. 15. Lower the vehicle. 16. Detach the coolant hose clamp. 17. Detach the coolant expansion tank. Position the tank to one side. 18. Using the special tool, remove the power steering pump pulley. 19. Disconnect the power steering pump high-pressure tube union. Allow the fluid to drain into a suitable container.

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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 .