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

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Removal 1. Disconnect the hood lamp harness. 1. Remove the hood insulator retainers and position the insulator away from the hood. 2. Disconnect the hood lamp harness retainers. 3. Disconnect the hood lamp electrical connector. 2. NOTE: Mark the hinge-to-hood placement to ease alignment when reinstalling the hood. Remove the hood. 1. Disconnect the windshield washer hose. 2. Remove the ground strap bolt. 3. Disconnect the hood struts. 4. Remove the four hinge-to-hood bolts and remove the hood. 3. Recover the air conditioning (A/C) system. For additional information, refer to Section 412-00. 4. Remove the lower intake manifold (9424). For additional information, refer to Intake Manifold—Lower in this section. 5. Remove the front air deflector. 1. Remove the jack handle. 2. Remove the screws. 3. Remove the air deflector. 6. Remove the radiator upper hose from the radiator. 7. Using the special tools, remove the fan blade and fan clutch. 8. Remove the fan shroud. 1. Remove the screws. 2. Lift and remove the fan shroud and fan blade, as a unit, out of the vehicle. 9. NOTE: To avoid disturbing the transmission oil cooler fittings, use a backup wrench. Disconnect the transmission fluid cooler fittings. 1. Disconnect the upper transmission fluid cooler fitting. 2. Disconnect the lower transmission fluid cooler fitting. 10. Disconnect the lower radiator hose from the radiator. 1. Pry the locking tab up and out of the slot. 2. Rotate the lower radiator hose. 3. Disconnect the lower radiator hose. 11. Disconnect the degas hose from the radiator. 1. Release the clamp. 2. Slide the hose off of the radiator fitting. 12. Remove the radiator. 1. Remove the bolts. 2. Remove the upper radiator support brackets, the jack handle and the wheel nut wrench retainers. 3. Lift the radiator off the radiator mounting insulators. 4. Remove the radiator mounting insulators. 13. Remove the accessory drive belt. For additional information, refer to Section 303-05. 14. Disconnect the generator electrical connectors. 1. B+ 2. Stator 3. Voltage regulator 15. Remove the lower bracket bolts and the generator. 16. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold. 17. Disconnect the transmission wiring harness retainers from the right cylinder head and position the harness aside. 18. Remove the bolts retaining the transmission to the engine. 19. Disconnect the bulkhead connectors. 20. Remove the ground strap retaining bolt. 21. Disconnect the degas return hose.

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NOTE: The LH fender is shown, the RH fender is similar. 1. NOTE: The pin-type retainers are a one-time use item, and new pin-type retainers must be installed after removal. If equipped with an engine compartment lamp, remove the pin-type retainers and position the hood insulation aside. 2. If equipped, release the wiring harness locators and disconnect the engine compartment lamp electrical connector. 3. NOTE: Two technicians needed to carry out this step. NOTE: Support the hood with a suitable hood support. Remove the hood. Mark the hinge locations and remove the hood hinge bolts. 4. Remove the front bumper cover. For additional information, refer to Section 501-19. 5. Remove the fender splash shield. For additional information, refer to Fender Splash Shield—LH or Fender Splash Shield—RH in this section. 6. Release the wiring harness and the hood latch release cable locators. 7. Remove the ground wire bolt. 8. Remove the pin-type retainer and position the rocker panel moulding aside. 9. Remove the fender rear bolts. 10. Remove the fender rear bolts. 11. Remove the fender upper bolts. 12. Remove the fender bolts. 13. Remove the fender brace bolt. 14. Remove the fender to radiator support bolts. 15. Remove the radiator grille opening panel bolt. 16. Remove the fender bolts. 17. Remove the radiator grille opening panel bolt. 18. NOTE: On the RH fender, an assistant is needed to support the fender when removing this bolt. Remove the fender rear bolt and the fender. Installation 1. Position the fender. 2. Install the fender rear bolts.

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1. Remove front bumper cover (17D957). Refer to Section 01-19. 2. Remove headlamps (13008) and parking lamps (13200). Refer to Section 17-01. 3. Remove Radiator Grille (8200) as outlined. 4. Remove screws from both sides of radiator support (16138). 5. Remove screws from both sides of radiator grille opening panel (8190) to front fender (16005). 6. Remove nuts from hood latch support (16707). 7. Remove screws from both sides of radiator grille opening panel bracket (8B455). 8. Remove screws retaining both sides of radiator grille opening panel brace (8B057) to radiator grille opening panel. 9. NOTE: If replacing only radiator grille opening panel, transfer all necessary parts to new radiator grille opening panel. To install, reverse Removal procedure. Tighten screws to 5-8 Nm (45-71 lb-in). Grille Opening Panel—Town Car Crown Victoria, Grand Marquis Removal and Installation 1. Remove front bumper cover. Refer to Section 01-19. 2. Remove Radiator Grille as outlined. 3. Remove headlamps and parking lamps. Refer to Section 17-01. 4. Remove screws from both sides of radiator support. 5. Remove screws from both sides of radiator grille opening panel bracket to radiator grille opening panel.

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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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1. Drill out four license plate rivets (if required). 2. Remove fog lamps (15200) (if equipped). 3. Remove two nuts and two screws retaining front bumper (17757) to each front fender (16005). 4. Remove one screw (3 on Cobra) retaining front bumper cover (17D957) to each front fender splash shield (16102). 5. Remove three pushpins retaining front bumper cover to radiator support (16138). 6. Remove two upper blind rivets retaining front bumper cover to radiator grille opening panel reinforcement (8A284). Front Bumper Cover 7. Remove two rivets retaining front bumper cover support (17C947) to front bumper. Remove center pins from rivets using a drift punch. Remove the remainder of the rivets using a drill. Use care not to enlarge the retaining holes in the sheet metal. 8. Remove LH and RH headlamp bulbs (13007). Refer to Section 17-01. 9. Insert a thin screwdriver blade between the underside of the front bumper cover and the radiator grille opening panel reinforcement to release the front bumper cover locking tabs on both LH and RH sides, underneath the headlamp opening. Remove the front bumper cover while the lock tabs are lifted. Front Bumper Cover Removal 11. On each side of vehicle (convertible only), remove one bolt and one nut retaining front bumper vibration damper to front bumper. Front Bumper Vibration Damper—Convertible