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HOMESERVICE MANUALSFORD2003WINDSTAR BASEREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1214 (ENGINE - 3.0L (4V))INSTALLATIONENGINE
2003 Ford Windstar Base

Section 1214 (Engine - 3.0L (4V)): Installation: Engine

2003 Ford Windstar BaseSECTION Engine
WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
Special Tool(s)

GFD15635Courtesy of FORD MOTOR COMPANY
 Lifting Bracket, Engine 303-050 (T70P-6000)
GFD15636Courtesy of FORD MOTOR COMPANY
 Powertrain Lift with Tilting Plate 014-00765
GFD15638Courtesy of FORD MOTOR COMPANY
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
GFD15637Courtesy of FORD MOTOR COMPANY
 Universal Adapter Brackets 014-0001
Material

Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent WSS-M2C930-A
Silicone Gasket and Sealant TA-30 WSE-M4G323-A4

Installation 

NOTE: If the oil pan was removed during engine disassembly, it must be installed after the engine and transaxle are assembled and the transaxle-to-engine bolts are installed. Failure to follow this assembly sequence can result in engine oil leaks.

All vehicles 

  • 1.

    Using the special tools, align the engine with the transaxle.
GFD15689Courtesy of FORD MOTOR COMPANY

  • 2.

    Install the 7 transaxle bolts.
    • Tighten to 40 Nm (30 lb-ft).
GFD15688Courtesy of FORD MOTOR COMPANY

  • 3.

    Using the special tools, secure the engine to the powertrain lift.
GFD15676Courtesy of FORD MOTOR COMPANY

All wheel drive (AWD) vehicles 

  • 4.

    Install 6 new RH exhaust manifold studs.
    • Tighten to 12 Nm (9 lb-ft).
GFD15687Courtesy of FORD MOTOR COMPANY

  • 5.

    Install a new gasket and the RH exhaust manifold and new nuts.
    • Tighten in the sequence shown below to 20 Nm (15 lb-ft).
Fig 1: RH Exhaust Manifold Nuts Tightening Sequence
GFD15783Courtesy of FORD MOTOR CO.

All vehicles 

  • 6.

    Connect the turbine speed sensor (TSS) electrical connector.
GFD15685Courtesy of FORD MOTOR COMPANY

  • 7.

    Attach the transaxle control harness to the brackets.
GFD15684Courtesy of FORD MOTOR COMPANY

  • 8.

    Connect the transaxle wiring harness electronic control switch electrical connector.
GFD15683Courtesy of FORD MOTOR COMPANY

  • 9.

    Connect the transmission range (TR) sensor electrical connector.
GFD15682Courtesy of FORD MOTOR COMPANY

  • 10.

    Attach the pin-type retainers to the transaxle support bracket and connect the heated oxygen sensor (HO2S) and catalyst monitor sensor electrical connectors.
GFD15681Courtesy of FORD MOTOR COMPANY

  • 11.

    Position the powertrain into the vehicle.
GFD15786Courtesy of FORD MOTOR COMPANY

  • 12.

    Install the front engine support nuts.
    • Tighten to 55 Nm (41 lb-ft).
GFD15680Courtesy of FORD MOTOR COMPANY

  • 13.

    Install the rear transaxle support bolt.
    • Tighten to 103 Nm (76 lb-ft).
GFD15679Courtesy of FORD MOTOR COMPANY

  • 14.

    Position the RH transaxle support insulator and install the bolt and nuts.
    • Tighten to 80 Nm (59 lb-ft).
GFD15678Courtesy of FORD MOTOR COMPANY

  • 15.

    Install the RH transaxle support insulator bolt.
    • Tighten to 115 Nm (85 lb-ft).
GFD15677Courtesy of FORD MOTOR COMPANY
    NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of the sealant application.
RENDER: 1.0x

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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.