This process is complex and varies slightly depending on the engine (3.0L V6 or 4.0L V6). A detailed step-by-step guide would be extremely lengthy. However, here's a general overview of the steps involved:
Preparation is Key:
* Consult a Repair Manual: Obtain a factory service manual specific to your 1993 Ford Aerostar. This is absolutely essential. It provides detailed instructions, torque specifications, and diagrams crucial for success. Haynes and Chilton manuals are also options, but the factory manual is generally preferred.
* Gather Tools: You'll need a comprehensive set of tools, including various wrenches, sockets, screwdrivers, a jack, jack stands, engine hoist (absolutely necessary), transmission jack (recommended), and potentially special tools like a torque wrench.
* Safety First: Work in a well-ventilated area. Disconnect the battery negative terminal. Use jack stands to securely support the vehicle. Wear safety glasses and gloves.
General Steps (Order may vary slightly depending on your engine and manual):
1. Disconnect Everything: Disconnect all electrical connectors, vacuum lines, fuel lines, and cooling system lines from the engine. Label everything meticulously to ensure correct reassembly.
2. Remove Ancillary Components: Remove components like the alternator, power steering pump, air conditioning compressor, and other accessories attached to the engine.
3. Drain Fluids: Drain the engine oil, coolant, and transmission fluid (if removing as one unit).
4. Detach Exhaust System: Disconnect and remove the exhaust manifolds and pipes from the engine.
5. Remove Transmission (Usually): In most cases, the transmission needs to be separated from the engine. This is a complex process and may require specialized tools and knowledge.
6. Disconnect Motor Mounts: Unbolt the engine mounts that secure the engine to the vehicle's frame.
7. Lift Engine with Hoist: Carefully use an engine hoist to lift the engine out of the engine bay. You'll likely need to maneuver it carefully to clear various parts of the vehicle.
Important Considerations:
* Weight: The engine is very heavy. You absolutely need an engine hoist and ideally a transmission jack for safety and to prevent damage.
* Accessibility: Working in the engine bay of an Aerostar can be cramped.
* Bolts and Fasteners: Many bolts may be corroded or seized, requiring penetrating oil and patience. Damaged fasteners may require replacement.
Recommendation:
Unless you are very experienced in automotive repair, strongly consider having a professional mechanic perform this task. The risks of damaging your vehicle or injuring yourself are significant. The cost of professional labor is likely far less than the cost of repairing damage caused by a failed DIY engine removal.
