Monday, March 12, 2012

How to Replace Engine on Ford Windstar?

The engine replacing procedure is as follows :---

REMOVAL & INSTALLATION details are provided below:---

  1. Remove or disconnect the following:
    Damage to the steering column air bag wiring can result if the steering wheel is allowed to rotate freely. The wire is wound like a watch spring and can be over-tightened and break if the steering wheel is rotated too far in either direction.

    Negative battery cable
    Refrigerant, into a refrigerant recovery station
    Cowl top vent panel
    Wiring from the alternator
    Air cleaner assembly
    Upper and lower radiator hoses from the engine
    Heater water hoses and secure to body
    Air conditioning discharge and suction hoses, then secure them to the engine. Cap the open lines to prevent moisture from entering the system.
    Accelerator cable and speed control cable from the throttle body lever
    Accelerator cable bracket from the throttle body
    Fuel supply and return lines from the fuel injection supply manifold
    All engine wiring harnesses from the engine and secure to the body
    All vacuum hoses from the engine
    Gear shift cable from the transaxle
  2. Lock the steering wheel with the wheels in the straight-ahead position by turning the ignition to the OFF position.
  3. Remove or disconnect the following:
    Do not allow the flex connector of the duel converter Y-pipe to hang unsupported or damage to the flex joint will result.

    The routing of the battery ground cable to the cylinder block is critical. It should go between the transaxle and the bracket. Take note during disassembly.

    Engine oil
    Transaxle cooler lines at the transaxle. Secure the lines to the radiator.
    Heated oxygen sensor wiring harness

    Dual converter Y-pipe and support it from the body

    Starter motor wires and secure out of the way
    Starter motor
    Engine rear plate and torque converter-to-flywheel nuts
    Power steering cooler lines
    Upper bolt from the sway bar links
    Dust boot from the steering rack pinion support
    Steering coupling pinch bolt from the steering column intermediate shaft at the steering gear
    Intermediate shaft from the steering gear
    Front stabilizer bar links
    Front suspension lower arms from the knuckles at the ball joint
    Tie rod ends from the knuckle
    Front axle wheel hub retainers from the halfshaft ends
    Halfshafts from the front wheel knuckle
  4. Support the front subframe, engine and transaxle assembly.
  5. Remove or disconnect the following:

    The 4 retaining bolts, and lower the engine transaxle and front subframe from the vehicle
    Power steering pressure hose from the power steering pump
  6. Attach an engine hoist and lift the engine slightly.
  7. Remove the engine support insulators.
  8. Lift the engine and transaxle assembly from the front subframe.
  9. Lower the engine and transaxle.
  10. Support the transaxle on a level stationary surface and separate the engine from the transaxle.
To install:
  1. If removed, install the transaxle on the engine.
  2. Install the engine on the subframe.
  3. Install the engine support insulators.
  4. Connect the power steering hose to the pump.
  5. Carefully raise the engine/transaxle assembly into the vehicle.
  6. Install the 4 subframe bolts.
  7. The remainder of the installation is the reverse of removal.
  8. Please note the following torque specifications:

    Engine-to-transaxle: 30-44 ft. lbs. (40-60 Nm)
    Torque converter nuts: 20-34 ft. lbs. (27-46 Nm)
    Subframe-to-body bolts: 57-76 ft. lbs. (77-103 Nm)
    Steering coupling pinch bolt: 25-34 ft. lbs. (34-46 Nm)
    Dual converter Y-pipe-to-exhaust manifold: 25-34 ft. lbs. (34-46 Nm)
    Flex pipe retaining bolts: 25-34 ft. lbs. (34-46 Nm)
    Accelerator cable bracket retaining bolts: 71-106 inch lbs. (8-12 Nm)
    Front engine support insulator-to-subframe (3.8L): 50-68 ft. lbs. (68-92 Nm)
    Front engine support insulator-to-subframe (3.0L): 65-87 ft. lbs. (88-119 Nm)
    Transmission insulator-to-subframe: 65-87 ft. lbs. (88-119 Nm)
    Rear engine and transaxle support insulator-to-subframe: 56-75 ft. lbs. (76-103 Nm)
  9. Refill the engine, transaxle and cooling system with the correct amount of the appropriate fluids before starting the engine.
This will help.

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