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Home › Ford › 2002 › Thunderbird › Repair and Diagnosis › Engine Mechanical › Mechanical › Engine - 3.9L › In-Vehicle Repair › Engine Front Cover › Installation

Engine Front Cover: Installation

  1. Install new gaskets.
    Fig 1: Installing Gaskets
    G03421474Courtesy of FORD MOTOR CO.
    2. 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, which ever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 2: Silicone Gasket & Sealant Application Locations
    G03421475Courtesy of FORD MOTOR CO.
  2. Apply silicone gasket and sealant in eight places.
  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.
      • Stage 1: Tighten to 5 N.m (44 lb-in).
      • Stage 2: Tighten to 10 N.m (89 lb-in).
    Fig 3: Engine Front Cover Bolt Tightening Sequence
    G03421476Courtesy of FORD MOTOR CO.
  4. Connect the five wiring harness clips.
    Fig 4: Connecting Wiring Harness Clips
    G03421477Courtesy of FORD MOTOR CO.
  5. Raise the vehicle.
    6. NOTE: The wiring harness is positioned behind the bracket.
    Fig 5: Installing Hydraulic Cooling Fan Pump Bracket
    G03421478Courtesy of FORD MOTOR CO.
  6. Install the hydraulic cooling fan pump bracket.
    7. NOTE: One bolt is blocked by the hydraulic cooling fan pressure hose and will have to be installed in stages.
    Fig 6: Installing Hydraulic Cooling Fan Pump
    G03421479Courtesy of FORD MOTOR CO.
  7. Install the hydraulic cooling fan pump.
  8. Install the hydraulic fan pump high pressure hose bracket.
    1. Install the bracket.
    2. Install the bolt.
    Fig 7: Installing Hydraulic Fan Pump High Pressure Hose Bracket
    G03421480Courtesy of FORD MOTOR CO.
  9. Connect the electrical connector.
    Fig 8: Connecting Electrical Connector
    G03421481Courtesy of FORD MOTOR CO.
  10. Connect the hydraulic cooling fan reservoir hose.
    Fig 9: Connecting Hydraulic Cooling Fan Reservoir Hose
    G03421482Courtesy of FORD MOTOR CO.
    11. NOTE: The wiring harness is positioned behind the bracket.
    Fig 10: Installing Power Steering Pump Bracket
    G03421483Courtesy of FORD MOTOR CO.
  11. Install the power steering pump bracket.
    12. NOTE: One bolt is blocked by the power steering pressure line and must be installed in stages.
    Fig 11: Installing Power Steering Pump
    G03421484Courtesy of FORD MOTOR CO.
  12. Install the power steering pump.
  13. Connect the Power Steering Pressure (PSP) switch.
    Fig 12: Connecting PSP Switch
    G03421485Courtesy of FORD MOTOR CO.
  14. Connect the power steering reservoir hose.
    Fig 13: Connecting Power Steering Reservoir Hose
    G03421486Courtesy of FORD MOTOR CO.
  15. Install the A/C compressor. For additional information, refer to AIR CONDITIONING .
  16. Install the crankshaft pulley. For additional information, refer to CRANKSHAFT PULLEY .
  17. Install the idler pulleys.
    Fig 14: Installing Idler Pulleys
    G03421487Courtesy of FORD MOTOR CO.
  18. Connect the heater hose.
    Fig 15: Connecting Heater Hose
    G03421488Courtesy of FORD MOTOR CO.
  19. Connect the lower radiator hose to the thermostat housing.
    Fig 16: Connecting Lower Radiator Hose To Thermostat Housing
    G03421489Courtesy of FORD MOTOR CO.
  20. Install the stud bolts.
    Fig 17: Installing Stud Bolts
    G03421490Courtesy of FORD MOTOR CO.
  21. Install the bracket.
    1. Install the bracket.
    2. Install the nuts.
    Fig 18: Installing Bracket
    G03421491Courtesy of FORD MOTOR CO.
  22. Position the water pump pulley and loosely install new bolts.
  23. Install the generator. For additional information, refer to GENERATORS & REGULATORS .
  24. Tighten the bolts in two stages.
    • Stage 1: Tighten to 10 N.m (89 lb-in).
    • Stage 2: Tighten an additional 45 degrees.
    Fig 19: Tightening Bolts
    G03421492Courtesy of FORD MOTOR CO.
  25. Install the engine cooling fan assembly. For additional information, refer to ENGINE COOLING .
  26. Install the RH valve cover. For additional information, refer to VALVE COVER RH .
  27. Install the LH valve cover. For additional information, refer to VALVE COVER LH .
  28. Fill the engine with clean engine oil.
    29. CAUTION: The cooling system filling and bleeding procedure must be followed exactly or damage to the engine can occur.
  29. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
  30. Fill and bleed the hydraulic cooling fan. For additional information, refer to ENGINE COOLING .
  31. Fill the power steering system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
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