Ford Crown Victoria, Mercury Grand Marquis Repair Manual 1989-2011

This Chilton DIY repair and service manual, covers 1989-2011 Ford Crown Victoria and Mercury Grand Marquis, powered by 4.6L and 5.0L V8 engines. U.S. and Canadian models.

NOTE: This Chilton 26180 Ford Crown Victoria / Mercury Grand Marquis repair manual does not include Mercury Marauder, 5.8L V8 engine information or information specific to natural gas-fueled models.

PISTONS/CONNECTING RODS | REMOVAL
(Refer to illustrations 13.1, 13.3a, 13.3b, 13.4, 13.6a, 13.6b, 13.7 and 13.8) NOTE: Prior to removing the piston/connecting rod assemblies, remove the cylinder head(s), the oil pan and the oil pump (on 5.0L engines) by referring to the appropriate Sections in Chapter 2, Part A or Part B, depending which engine is being overhauled.

1. Use your fingernail to feel if a ridge has formed at the upper limit of ring travel (about 1/4 inch down from the top of each cylinder). If carbon deposits or cylinder wear have produced ridges, they must be completely removed with a special tool. Failure to remove the ridges before attempting to remove the piston/connecting rod assemblies may result in piston breakage.
NOTE: Do not let the tool cut into the ring travel area more than 1/32-inch.
2. After the cylinder ridges have been removed, turn the engine upside-down so the crankshaft is facing up.
3. Before the connecting rods are removed, check the endplay with a dial indicator (see illustration) or with feeler gauges (see illustration). Slide them between the first connecting rod and the crankshaft throw feeler gauge(s). If the endplay exceeds the service limit, new connecting rods will be required. If new rods (or a new crankshaft) are installed, the endplay may fall under the specified minimum (if it does, the rods will have to be machined to restore it. Consult an automotive machine shop for advice if necessary). Repeat the procedure for the remaining connecting rods.

HEATER BLOWER MOTOR | REMOVAL AND INSTALLATION REMOVAL
(Refer to illustration 10.3)

1. Disconnect the blower motor electrical connector from the motor (see illustration 9.3).
2. Remove the cooling tube from the underside of the blower motor.
3. Remove the retaining screws, from the blower motor mounting plate (see illustration).
4. Turn the blower motor slightly to the right so that the bottom edge of the mounting plate aligns with the contour of the wheel-well splash panel. While still in the blower housing, lift the motor assembly up and maneuver it out of the heater housing assembly.
INSTALLATION NOTE: If the blower motor is being replaced, the fan wheel should be transferred to the new motor at this time. It is attached to the blower motor shaft with a push nut. Grasp the nut with pliers and pull it off or get a small screwdriver under it and pry it off, being careful not to crack the push nut. To reinstall the nut, simply push it on to the shaft.
5. Position the motor and fan assembly so that the bottom edge (the straight portion) follows the contour of the wheel-well splash panel. Maneuver the assembly past the wheel-well splash panel and into the top portion of the housing opening, then down into position.
6. The remainder of the installation is the reverse of removal.