2003 Ford Windstar BaseFACTORY OEM SERVICE PROCEDURE

Engine Front Cover: Removal

CAUTION: During engine repair procedures cleanliness is extremely important, any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.
  1. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. Drain the engine cooling system. For additional information, refer to ENGINE COOLING .
  3. Remove the cowl extension panel. For additional information, refer to FRONT END BODY PANELS .
  4. Disconnect the degas bottle hose.
    Fig 1: Identifying Degas Bottle Hose
    G01307701Courtesy of FORD MOTOR CO.
  5. Remove the generator. For additional information, refer to GENERATOR .
  6. Remove the idler pulley.
    Fig 2: Identifying Idler Pulley
    G01307702Courtesy of FORD MOTOR CO.
  7. Unclip the A/C wiring harness from the generator bracket brace.
    Fig 3: Unclipping A/C Wiring Harness From Generator Bracket Brace
    G01307703Courtesy of FORD MOTOR CO.
  8. Remove the bolts, generator bracket and the generator bracket brace as an assembly.
    Fig 4: Identifying Generator Bracket Brace Bolt
    G01307704Courtesy of FORD MOTOR CO.
  9. Disconnect the oil pressure sender electrical connector.
    Fig 5: Locating Oil Pressure Sender Electrical Connector
    G01307705Courtesy of FORD MOTOR CO.
  10. Disconnect the A/C compressor electrical connector.
    Fig 6: Locating A/C Compressor Electrical Connector
    G01307706Courtesy of FORD MOTOR CO.
  11. Disconnect the intake manifold runner control (IMRC) electrical connector.
    Fig 7: Locating Intake Manifold Runner Control (IMRC) Electrical Connector
    G01307707Courtesy of FORD MOTOR CO.
  12. Disconnect the camshaft position sensor electrical connector and position the wiring harness aside.
    Fig 8: Disconnecting Camshaft Position Sensor Electrical Connector
    G01307708Courtesy of FORD MOTOR CO.
  13. Remove the power steering pump. For additional information, refer to POWER STEERING .
  14. Disconnect the hoses from the water pump outlet tube.
    Fig 9: Disconnecting Hoses From Water Pump Outlet Tube
    G01307709Courtesy of FORD MOTOR CO.
  15. Remove the camshaft synchronizer. .
  16. Remove the bolts and the power steering mounting bracket.
    Fig 10: Identifying Power Steering Mounting Bracket Bolt
    G01307710Courtesy of FORD MOTOR CO.
  17. Remove the crankshaft pulley. For additional information, refer to CRANKSHAFT PULLEY .
  18. Remove the crankshaft position (CKP) sensor. .
  19. Disconnect the catalyst monitor sensor electrical connector.
    Fig 11: Locating Catalyst Monitor Sensor Electrical Connector
    G01307711Courtesy of FORD MOTOR CO.
  20. Remove the catalyst monitor sensor mounting bracket.
    Fig 12: Identifying Catalyst Monitor Sensor Mounting Bracket Nut
    G01307712Courtesy of FORD MOTOR CO.
  21. Remove the belt tensioner. For additional information, refer to ACCESSORY DRIVE .
  22. Remove and discard the oil filter.
    Fig 13: Identifying Oil Filter
    G01307713Courtesy of FORD MOTOR CO.
  23. Disconnect the radiator lower hose.
    Fig 14: Disconnecting Radiator Lower Hose
    G01307714Courtesy of FORD MOTOR CO.
  24. Remove the engine mount nuts.
    Fig 15: Identifying Engine Mount Nuts
    G01307715Courtesy of FORD MOTOR CO.
  25. Install the special tools.
    Fig 16: Identifying special tools (303-D095)
    G01307716Courtesy of FORD MOTOR CO.
  26. Install the engine lifting equipment and raise the engine 127 mm (5.08 in) .
    Fig 17: Lifting Engine
    G01307717Courtesy of FORD MOTOR CO.
  27. Remove the four bolts and the water pump pulley.
    Fig 18: Identifying Water Pump Pulley Bolt
    G01307718Courtesy of FORD MOTOR CO.
  28. Remove the water pump.
    • Remove the five nuts.
    • Remove the four bolts.
    • Remove the water pump, lower tube and gasket as an assembly.
      Fig 19: Identifying Water Pump
      G01307719Courtesy of FORD MOTOR CO.
  29. Remove the water pump mounting studs.
    Fig 20: Identifying Water Pump Mounting Studs
    G01307720Courtesy of FORD MOTOR CO.
    30. CAUTION: The cap screw is hidden by the oil filter adapter. Failure to remove this retainer will result in damage to the engine front cover.
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.

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