SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSFORD2003WINDSTAR BASEREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1009 (ENGINE -- 4.0L SOHC)IN-VEHICLE REPAIRENGINE FRONT COVERINSTALLATION
2003 Ford Windstar Base

Engine Front Cover: Installation

2003 Ford Windstar BaseSECTION Installation
WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
  1. Clean and inspect the gasket mating surfaces. Use silicone gasket remover and metal surface prep and a plastic or wooden scraping tool. Follow the directions on the packaging.
  2. Position the front cover gasket.
    CAUTION: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
  3. Apply silicone gasket and sealant to the oil pan and engine block mating surfaces.
    Fig 1: Applying Silicone Gasket And Sealant To Oil Pan And Engine Block Mating Surfaces
    G03913814Courtesy of FORD MOTOR CO.
  4. Apply silicone gasket and sealant to the front cover in 2 places.
    Fig 2: Applying Silicone Gasket And Sealant To Front Cover In Places
    G03913815Courtesy of FORD MOTOR CO.
    5. NOTE: Make sure the stud bolts are installed in their original positions.
  5. Position the front cover and install the 10 bolts.
    • Tighten to 19 Nm (14 lb-ft).
    6. NOTE: Make sure the coolant bypass hose is attached to the coolant pump.
  6. Position the thermostat housing and install the 3 bolts.
    • Tighten to 11 Nm (8 lb-ft).
  7. Position the bypass hose clamp.
  8. Connect the upper radiator hose to the thermostat housing and position the clamp.
  9. Connect the heater hose to the thermostat housing and position the clamp.
  10. Connect the ECT sensor electrical connector.
  11. Install new wiring harness retainers and position the CKP sensor wiring.
  12. Connect the CKP sensor electrical connector.
  13. Position the LH accessory drive bracket and install the 4 bolts.
    • Tighten to 42 Nm (31 lb-ft).
  14. Install the 2 coil bracket-to-LH accessory drive bracket bolts.
    • Tighten to 10 Nm (89 lb-in).
  15. Position the alternator bracket and install the 3 bolts.
    • Tighten to 42 Nm (31 lb-ft).
  16. Connect the alternator electrical connectors and the wiring harness retainer.
    • Tighten to 8 Nm (71 lb-in).
  17. Connect the heater hose to the coolant pump and position the clamp.
  18. Position the drive belt tensioner and install the bolt.
    • Tighten to 47 Nm (35 lb-ft).
  19. Connect the lower radiator hose and position the clamp.
  20. Install the 5 oil pan-to-front cover bolts.
    • Tighten to 9 Nm (80 lb-in).
  21. Position the power steering pressure tube and install the 2 nuts.
    • Tighten to 18 Nm (13 lb-ft).
  22. Install the crankshaft front seal. For additional information, refer to CRANKSHAFT FRONT SEAL .
  23. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  24. Fill the engine cooling system For additional information, refer to ENGINE COOLING .
RENDER: 1.0x

NO RELATED

Recommended Tools & Savings

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Affiliate disclosure: We may earn a commission at no extra cost to you.

Shop Manual-Ready ToolsFree Quote CheckQuote Shield Pro

When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.