Removal and Installation

WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford F550 Super Duty, 2003 Ford F450 Super Duty, 2003 Ford Excursion, and 2003 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Drain the cooling system. Refer to Cooling System Draining, Filling and Bleeding .
Remove the cooling system fan and fan clutch. Refer to COOLING FAN - Blade, Clutch and Shroud, 5.4L, 6.8L, 7.3L Diesel .
Remove the three water outlet bolts. Remove the thermostat housing. Remove the thermostat and O-ring.

Fig 1: Removing & Installing Thermostat Housing
Courtesy of FORD MOTOR CO.
Remove the accessory drive belt. Refer to ACCESSORY DRIVE .

NOTE: The coolant pump pulley is removed for clarity.

Fig 2: Disconnecting Heater Hose From Coolant Pump

Courtesy of FORD MOTOR CO.

Disconnect the heater hose from the coolant pump.
Remove the two bolts and the coolant outlet tube.

Fig 3: Removing Bolts And Coolant Outlet Tube
Courtesy of FORD MOTOR CO.
Disconnect the engine coolant temperature (ECT) sensor connector.

Fig 4: Disconnecting Engine Coolant Temperature (ECT) Sensor Connector
Courtesy of FORD MOTOR CO.
Disconnect the camshaft position sensor electrical harness from the coolant pump.
1. Remove the bolt.
2. Disconnect the pin-type retainer and position the harness away from the coolant pump.
  
  Fig 5: Disconnecting Camshaft Position Sensor Electrical Harness From Coolant Pump
  Courtesy of FORD MOTOR CO.
Remove the four bolts and the coolant pump pulley.

Fig 6: Removing Bolts And Coolant Pump Pulley
Courtesy of FORD MOTOR CO.
Remove the six bolts and the coolant pump.

Fig 7: Removing Bolts And Coolant Pump
Courtesy of FORD MOTOR CO.
Clean the coolant pump gasket surfaces.
To install, reverse the removal procedure.