Ford Freestar, Monterey 2004-2006

Engine

Print

Removal & Installation



  1. Relieve the fuel system pressure.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Recover the air conditioning refrigerant, into a refrigerant recovery station
  6.  
  7. 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.



    Both battery cables
     
    Wiper motor
     
    Cowl top panel
     
    Air cleaner assembly
     
    Fuel supply manifold lines
     
    Power steering pump
     
    Starter
     



    Dual converter Y-pipe and support it from the body
     
    Accelerator and cruise control cables from throttle assembly
     
    Accelerator cable bracket
     
    Upper and lower radiator hoses from the engine
     
    Heater water hoses and secure to body
     
    Positive terminal from Power Distribution Box (PDB)
     
    PDB 68-pin connector
     
    Engine wiring retainers
     
    Shift cable
     
    Evaporative (EVAP) return tube
     
    EVAP canister connector and vacuum line
     
    Brake booster vacuum line
     
    Powertrain Control Module (PCM)
     
    Engine grounds (3)
     
    Radiator shield
     
    Passenger side engine roll restrictor

    Click image to see an enlarged view

    Fig. Removing passenger side engine roll restrictor-Freestar and Monterey

     
    A/C compressor and wire aside
     
    Power steering cooler line
     
    Transaxle cooler lines
     
    Steering column pinch bolt
     
    Oil pan-to-transaxle bolts
     
    Torque converter nuts (4)
     
    Brake calipers and wire aside
     
    ABS connectors
     
    Stabilizer bar links
     
    Lower strut bolts on both sides
     
    Position subframe support tool 014-00765 under subframe
     
    Subframe bolts and lower the engine, transaxle and subframe assembly

    Click image to see an enlarged view

    Fig. Removing stabilizer bar links-Freestar and Monterey



    Click image to see an enlarged view

    Fig. Installing subframe support tool-Freestar and Monterey

     
    Alternator brace
     
    A/C compressor and wire aside
     
    Driver side engine roll restrictor

    Click image to see an enlarged view

    Fig. Removing driver side engine roll restrictor-Freestar and Monterey

     
    Label and remove remaining electrical connectors
     
    Transaxle fluid level tube
     
    Install suitable engine lifting device
     
    Bell housing bolts (4)
     
    Engine mount bolts
     
    Transaxle mount bolts
     
    Engine
     

  8.  

To install:

  1. Position the engine onto the transaxle and subframe assembly.
  2.  
  3. Install the transaxle mount bolts. Torque the bolts to 46 ft. lbs. (63 Nm).
  4.  
  5. Install the oil pan-to-transaxle bolt. Torque the bolt to 33 ft. lbs. (45 Nm).
  6.  
  7. Install the engine mount bolts. Torque the bolts to 66 ft. lbs. (90 Nm).
  8.  
  9. Install the bell housing bolts. Torque the bolts to 37 ft. lbs. (50 Nm).
  10.  
  11. Install or connect the following:

    Transaxle fluid level tube
     
    Under vehicle electrical connectors
     
    Driver side roll restrictor bracket. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    A/C compressor. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Generator brace
     
    Raise the engine, transaxle and subframe assembly
     
    Subframe bolts. Torque the bolts to 66 ft. lbs. (90 Nm).
     
    Lower strut bolts. Torque the bolts to 91 ft. lbs. (124 Nm).
     
    Stabilizer bar link bolts. Torque the bolts to 70 ft. lbs. (95 Nm).
     
    ABS connectors
     
    Brake calipers. Torque the bolts to 26 ft. lbs. (35 Nm).
     
    Torque converter bolts. Torque the bolts to 27 ft. lbs. (36 Nm).
     
    Oil pan-to-transaxle bolts. Torque the bolts to 33 ft. lbs. (45 Nm).
     
    Steering column pinch bolt. Torque the bolts to 30 ft. lbs. (40 Nm).
     

  12.  
  13. The remainder of the installation is the reverse of removal.
  14.  
  15. Please note the following torque specifications:

    Passenger side roll restrictor. Torque the bolts to 46 ft. lbs. (63 Nm).
     

  16.  
  17. Refill the engine, transaxle and cooling system with the correct amount of the appropriate fluids before starting the engine. Recharge the A/C system using approved recycling equipment.
  18.  

 
label.common.footer.alt.autozoneLogo