2004 Ford ThunderbirdFACTORY OEM SERVICE PROCEDURE

Engine Front Cover

MATERIAL SPECIFICATION

Item Specification
Metal Surface Cleaner F4AZ-19A536-RA or equivalent WSE-M5B392-A
Silicone Gasket and Sealant F7AZ-19554-EA (in Canada CXC-111-B) or equivalent WSE-M4G323-A4
    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 .
  4. Remove the RH valve cover. For additional information, refer to VALVE COVER RH .
  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 .
  7. Remove the A/C compressor. For additional information, refer to CLIMATE CONTROL SYSTEM .
  8. Remove the components in the order indicated in the following illustration and table.
    9. Fig 1: Removing Engine Front Side Components
    G03280715Courtesy of FORD MOTOR CO.
  9. To install, reverse the removal procedure.

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
    G03280716Courtesy of FORD MOTOR CO.
  2. Disconnect the heater hose.
  3. Remove the stud bolt.
    Fig 3: Disconnecting Heater Hose
    G03280717Courtesy of FORD MOTOR CO.
    4. NOTE: One bolt is blocked by the power steering pressure hose and must be removed with the power steering pump.
Factory Service Tools

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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.