Removal and Installation

CAUTION: The cooling system filling and bleeding procedure must be followed exactly or damage to the engine can occur.
1. Drain the engine cooling system. For additional information, refer to ENGINE COOLING .
2. Drain the engine oil.
3. Remove the LH valve cover. For additional information, refer to VALVE COVER LH  in this section.
4. Remove the RH valve cover. For additional information, refer to VALVE COVER RH  in this section.
5. Remove the engine cooling fan assembly. For additional information, refer to ENGINE COOLING .
6. Remove the crankshaft pulley and crankshaft seal. For additional information, refer to CRANKSHAFT PULLEY AND CRANKSHAFT SEAL  in this section.
7. Remove the A/C compressor. For additional information, refer to ENGINE COOLING .
8. Remove the components in the order indicated in the following illustration and table.
9. To install, reverse the removal procedure.
   Fig 1: Removing Engine Front Cover With Gasket

   Courtesy of FORD MOTOR CO.

Items 1, 2 and 3: Engine Front Cover Removal Note 

1. Disconnect the lower radiator-to-thermostat housing hose.
   Fig 2: Disconnecting Lower Radiator-To-Thermostat Housing Hose

   Courtesy of FORD MOTOR CO.
2. Disconnect the heater hose.
   Fig 3: Disconnecting Heater Hose

   Courtesy of FORD MOTOR CO.
3. Remove the stud bolt.
   Fig 4: Removing Stud Bolt

   Courtesy of FORD MOTOR CO.
NOTE: One bolt is blocked by the power steering pressure hose and must be removed with the power steering pump.
Fig 5: Removing Power Steering Pump With Bolts
Courtesy of FORD MOTOR CO.
4. Remove the bolts and position the power steering pump aside.
5. Remove the coolant pump pulley bolts and the pulley.
   Fig 6: Locating Coolant Pump Pulley Bolts And Pulley For Removal

   Courtesy of FORD MOTOR CO.
6. Remove the power steering pump bracket.
   Fig 7: Removing Power Steering Pump Bracket

   Courtesy of FORD MOTOR CO.
7. Disconnect the five wiring harness clips.
   Fig 8: Disconnecting Five Wiring Harness Clips

   Courtesy of FORD MOTOR CO.
8. Remove the engine front cover.
   • Remove the bolts in the sequence shown. See Fig 9.
   • Remove the engine front cover.
   Fig 9: Identifying Engine Front Cover Bolts Removal Sequence

   Courtesy of FORD MOTOR CO.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
Fig 10: Identifying Sealing Surfaces For Cleaning
Courtesy of FORD MOTOR CO.
9. Clean the sealing surfaces with metal surface cleaner.

Items 1, 2 and 3: Engine Front Cover Installation Note 

1. Install new gaskets.
   Fig 11: Installing New Gaskets

   Courtesy of FORD MOTOR CO.
NOTE: If the front cover is not secured within four minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Fig 12: Applying Silicone Gasket And Sealant
Courtesy of FORD MOTOR CO.
2. Apply silicone gasket and sealant in the eight places shown. See Fig 12.
3. Install the engine front cover.
   • Position the engine front cover on the cylinder block.
   • Loosely install the bolts.
   • Tighten the bolts in two stages in the sequence shown. See Fig 13.
     • Stage 1: Tighten to 5 N.m (44 lb-in).
     • Stage 2: Tighten to 10 N.m (89 lb-in).
   Fig 13: Identifying Engine Front Cover Bolts Tightening Sequence
   Courtesy of FORD MOTOR CO.
4. Connect the five wiring harness clips.
   Fig 14: Connecting Five Wiring Harness Clips

   Courtesy of FORD MOTOR CO.
NOTE: The wiring harness is positioned behind the bracket.
Fig 15: Installing Power Steering Pump Bracket
Courtesy of FORD MOTOR CO.
5. Install the power steering pump bracket.
6. Install the coolant pump pulley and bolts and tighten in 2 stages:
   • Stage 1: Tighten to 10 N.m (89 lb-in).
   • Stage 2: Tighten an additional 45 degrees.
   Fig 16: Installing Coolant Pump Pulley And Bolts

   Courtesy of FORD MOTOR CO.
NOTE: One bolt is blocked by the power steering pressure line and must be installed with the power steering pump.
Fig 17: Installing Power Steering Pump With Bolts
Courtesy of FORD MOTOR CO.
7. Position the power steering pump and install the bolts.
8. Connect the heater hose.
   Fig 18: Connecting Heater Hose

   Courtesy of FORD MOTOR CO.
9. Connect the lower radiator hose to the thermostat housing.
   Fig 19: Connecting Lower Radiator Hose To Thermostat Housing

   Courtesy of FORD MOTOR CO.
10. Install the stud bolt.
    Fig 20: Installing Stud Bolt

    Courtesy of FORD MOTOR CO.