How to Replace Engine on Ford Windstar?

The engine replacing procedure is as follows :---


Engine
REMOVAL & INSTALLATION details are provided below:---

1. Remove or disconnect the following:
   
   NOTE

   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

   Coolant

   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:
   
   NOTE

   Do not allow the flex connector of the duel converter Y-pipe to hang unsupported or damage to the flex joint will result.
   
   
   
   NOTE

   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.
   
   
   
   
   Wheels

   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.

Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html