Top 10 2004 Ford Freestar Questions & Answers

Click on the following free direct Link. It has the correct Serpentine/Drive Belt Diagram for your 2004 Ford Freestar. You either have the 3.9L or 4.2L V6 Engine. I am not sure what Engine options (AC/No AC, etc.) you have. If this Diagram is not correct: check on the underside of your Hood for the correct Belt Diagram. However the below "How To" remains accurate.

http://www.2carpros.com/car_repair_information/year/2004/make/ford/model/freestar/2004_ford_freestar_drive_belt_routing_diagram.htm

"HOW TO":
Standard Rules to Removal the Serpentine Belt with an Automatic Tensioner:
1. Find the Tensioner(s). (See Diagram on Link)
2. Using a Serpentine Belt Tensioner Tool, Or Wrench OR Ratchet, Rotate/Move the Tensioner USING THE AVAILABLE NUT (on the Pulley or Arm Base) OR the OPENING (3/8ths or 1/2 inch square opening) rotating the Tensioner Pulley/Arm - moving it away from contact with the belt and towards the area where the belt is not in contact with the Tensioner Pulley. The Tensioner is spring loaded, and is hard to rotate/move.
3. Remove the loosened belt off one of the other more easily accessed Pulleys.
4. DO NOT quickly release the Tensioner, but gently allow the Tensioner to rest in its closed position.

Standard Rules for Installing the Serpentine Belt with an Automatic Tensioner:
a. Pick a Pulley that is most easily accessed. This will usually be on top. This will be the last Pulley that the belt will go on.
b. Using the Diagram: Install the new Serpentine Belt on the remainder of the Pulleys....over, under, left right.
c. Using a Serpentine Belt Tensioner Tool or Wrench or Ratchet Tool: Rotate/Move the Tensioner Pulley/Arm "away" from Belt contact area on the Tensioner. This spring is pretty hard and with a new belt, it will be even harder to install. Rotate/Move this to as-close to the maximum allowed inorder to have enough slack in the belt to get it up and over the last pulley.
d. Using your other hand - Pull the Belt up and over the Last remaining Pulley.
e. Before releasing the pressure on the Tensioner, visually inspect the remainder Pulleys and the Belts' Positioning on them.
Let me know if this helped, or if you have additional information questions. Feel Free to contact me at FixYa.com!

Remove the 2 bolts from handle, #2 from picture. Remove 2 screws from either side of door pane(#4) now just the clips hold it on, pull panel off at one corner and work your way around until its completely removed.
Thank you and good luck,
Lee

you may find the fuse diagram on the inside of the fuse box cover of the fuse box under the hood....hope this helps.....cheers

The EGR valve is on top of the engine towards the driver's side. The assembly looks like a small canister with the top half crimped on, it has a large tube coming up from the exhaust, 1 electrical connector and red/black vacuum lines as well.

My CEL was on and I was getting horrible gas mileage. First I disconnected the battery. On top of the EGR valve there is a small plastic cover. After carefully removing this (mine was brittle) you can remove the sofe grey foam air filter. Mine was very dirty, I cleaned it with alcohol, let it dry and put it back on. I also removed all the electrical and vacuum lines and sprayed them with mass air flow sensor cleaner.

After getting it all together and reconnecting the battery the check engine light is off. Today I will drive it and see if the gas mileage has improved.

The blend door is not working right or the in car air temperature sensor is faulty.
Removal & Installation Air Inlet Door Vacuum Motor To Remove:

1. Remove the instrument panel.
2. Remove the air inlet door motor mounting screws. CAUTION
   Do not attempt to bend any part of the air inlet duct door lever.
   
3. Rotate and remove the air inlet door vacuum control motor.

To Install:

1. Rotate and install the air inlet door vacuum control motor.
2. Install and tighten the mounting screws.
3. Install the instrument panel.

Defroster Door Vacuum Motor To Remove:

1. Remove the passenger air bag module from the instrument panel.
2. Disconnect the vacuum line and remove the mounting screws. CAUTION
   Do not attempt to bend any part of the defroster airflow mode door lever.
   
3. Rotate and remove the vacuum control motor from the defrost door lever.

To Install:

1. Rotate and install the vacuum control motor on the defrost door lever.
2. Install and tighten the mounting screws.
3. Connect the vacuum line to the vacuum control motor.
4. Install the passenger's air bag module.

Floor Console Register Duct Vacuum Motor To Remove:

1. Remove the floor console.
2. Remove the right-side instrument panel insulator.
3. Working from the passenger's footwell, disconnect the vacuum hose.
4. Remove the screws and the floor console register duct vacuum control motor. CAUTION
   Do not attempt to bend any part of the floor console register duct door lever.
   
5. Rotate and remove the vacuum control motor from the floor console register duct door.

To Install:

1. Rotate and install the vacuum control motor on the floor console register duct door.
2. Install and tighten the mounting screws.
3. Connect the vacuum hose to the floor console register duct vacuum control motor.
4. Install the insulator under the dash.
5. Install the floor console.

Panel/Floor Door Vacuum Motor To Remove:

1. Working through the driver footwell, remove the two screws and the shield. CAUTION
   Do not attempt to bend any part of the airflow mode door lever.
   
2. Label and disconnect the two vacuum hoses.
3. Remove the mounting screw.
4. Lift, rotate and remove the panel/floor door vacuum control motor from the door lever.

To Install:

1. Install the panel/floor door vacuum control motor on the door lever.
2. Install and tighten the mounting screw.
3. Connect the vacuum hoses in their original positions.
4. Install the shield on the vacuum motor.

Auxiliary Air Distribution Blend Door Actuator To Remove:

1. Remove the right rear quarter trim panel access panel. Auxiliary climate control housing removal and installation
   
   
2. Remove the auxiliary air distribution blend door actuator screws.
3. Disconnect the auxiliary air distribution blend door actuator connector.

To Install:

1. Connect the auxiliary air distribution blend door actuator connector.
2. Install the auxiliary air distribution blend door actuator screws.
3. Install the right rear quarter trim panel access panel.

Auxiliary Temperature Blend Door Actuator To Remove:

1. Remove the right rear quarter trim panel. Auxiliary climate control housing removal and installation
   
   
2. Disconnect the temperature auxiliary temperature blend door actuator connector.
3. Remove the temperature auxiliary temperature blend door actuator screws.
4. Remove the temperature auxiliary temperature blend door actuator.

To Install:

1. Install the temperature auxiliary temperature blend door actuator.
2. Install the temperature auxiliary temperature blend door actuator screws.
3. Connect the temperature auxiliary temperature blend door actuator connector.
4. Install the right rear quarter trim panel.

--- In-Car Temperature Sensor Removal & Installation To Remove:

1. Remove the instrument cluster finish panel.
2. Disconnect the in-vehicle temperature sensor connector.
3. Disconnect the in-vehicle temperature sensor aspirator tube.
4. Remove the in-vehicle temperature sensor screws.
5. Remove the in-vehicle temperature sensor.

To Install:

1. Install the in-vehicle temperature sensor.
2. Install the in-vehicle temperature sensor screws.
3. Connect the in-vehicle temperature sensor aspirator tube.
4. Connect the in-vehicle temperature sensor connector.
5. Install the instrument cluster finish panel.

Here's how I repaired mine. Go inside and remove the plastic 2" square plastic cover. By pushing on the lever inside this area, the latch will release. Push on the door at the same time, when the latch is pushed. With the door open, remove all four screws from the plastic panel. Now pry carefully the big plastic panel off the door. There are plastic snaps holding this on, all around the edges. Now there is another metal cover over the latch mechanism under this panel. Remove this. You now can see into the latch area and put the handle back into the slot where it came out of. You'll see that the ends of the handle can be put back on the round bar, but to hold them in place, I attached 2 nylon ties on one end. You can also purchase a metal push on retainer from the local hardware store. Mine has been repaired for 8 months and had no trouble. Ford used no retainer on these handles and after prolonged use, they bend and the handle can be pulled off. A twenty minute job. Your wife can even do it.
Fred C

PO193 ---Fuel Rail Pressure Sensor Circuit
High Input (FRP)

Check Fuel Pressure at Rail

Please let me know if you have more questions, and thanks for using FixYa.

Look in ur 2004 freestar book and find the fuse it should be #9 (PATS FUSE)under the driver dash. Take the fuse out the lil red light on dash will not light anymore and ur van will start and keep the fuse out.

The spark plug firing order is ( 1 - 4 - 2 - 5 - 3 - 6 )

The engine cylinders are 1 , 2 , 3 from front to rear on the passenger side of the engine and 4 , 5 , 6 from front to rear on the drivers side of the engine

The coil pack towers are numbered 1 , 2 , 3 from front to rear in the row nearest the passenger side and 5 , 6 , 4 from front to rear in the row nearest the drivers side

hope this clarifies the situation for you