Ford Windstar, Ford Freestar, Mercury Monterey Repair Manual 1995-2007

TIMING CHAIN AND SPROCKETS | CHECK, REMOVAL AND INSTALLATION TIMING CHAIN DEFLECTION CHECK (Refer to illustration 10.3) NOTE: Timing chain deflection increases due to wear. The following check is a method of measuring wear without disassembling the engine.

1. Remove the left (front) valve cover (see Section 4).
2. Loosen the number 5 cylinder exhaust rocker arm bolt. This is the fourth rocker arm from the drive belt end of the engine. Rotate the rocker arm aside.
3. Install a dial indicator on the end of the pushrod (see illustration).
4. Rotating the crankshaft clockwise, position the engine with cylinder number one at TDC on the compression stroke (see Section 3).
5. Zero the dial indicator.
6. Slowly turn the crankshaft counterclockwise until the first movement is seen on the dial indicator. Stop and observe the timing marks to determine the number of degrees from TDC.
7. If the reading exceeds 6 degrees, replace the timing chain and sprockets.
TIMING CHAIN COVER REMOVAL
(Refer to illustrations 10.16a, 10.16b, 10.18 and 10.19) NOTE: The timing chain cover can't be removed on the 3.8L engine with the engine in-vehicle. Refer to Part B of this Chapter for engine removal.
8. Disconnect the negative cable from the battery (see Chapter 1).
9. Drain the cooling system and remove the drive belt(s) (see Chapter 1).

POWER STEERING PUMP | REMOVAL AND INSTALLATION REMOVAL
(Refer to illustrations 20.5a, 20.5b, 20.7 and 20.8) NOTE: The power steering pump is located at the front left corner of the engine on all Windstar models. On 3.0L and 1995 through 1998 3.8L engines, the reservoir is part of the pump. On 1999 and later 3.8L engines and all 3.9L and 4.2L engines, the reservoir is a separate unit, located at the right rear of the engine compartment, near the engine coolant reservoir.

1. Disconnect the cable from the negative terminal of the battery.
2. Place a drain pan under the power steering pump. Remove the drive belt (see Chapter 1).
3. On Windstar models, refer to Chapter 5 and remove the alternator. On Freestar/Monterey models, remove the two cowl grille panels (see Chapter 11).
4. On 3.0L models, refer to Chapter 2 and remove the drive belt tensioner.
5. Remove the pressure and return hoses from the pump and allow the fluid to drain (see illustrations). Plug the hoses to prevent contaminants from entering.