FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS
| WARNING | Fuel system is under pressure. Pressure must be released before servicing fuel system components. |
- Disconnect battery ground cable. Remove fuel cap to release fuel tank pressure. Using EFI Pressure Gauge (T80L-9974-B), release fuel pressure from fuel-pressure relief valve on fuel rail.
- To disconnect fuel lines, remove retaining clip from outside of fuel line coupling. Use Spring Lock Coupling Remover (D87L-9280-A) for 3/8" line or (D87L-9280-B) for 1/2" line. Install spring lock coupling remover on fuel line coupling so it enters cage opening. (Scheme 68)
- Push spring lock coupling remover into cage opening to release female fitting from garter spring. Pull couplings apart. Remove spring lock coupling remover.
- When installing fuel lines, install NEW "O" rings on fuel lines. Use only specified fuel resistant "O" rings (Brown). Before installing, lightly coat with clean engine oil. Clean fittings, and replace garter spring (if necessary). Fit female fitting to male fitting and push until garter spring snaps over flared end of female fitting.
- Ensure lines are locked together and garter spring is over female fitting flared end. Install retaining clip. Ensure horseshoe portion of clip is over coupling. DO NOT install retaining clip over rubber fuel line. NOTE: Install Black retaining clip on fuel supply line and Gray clip on fuel return line.
Scheme 68
Note. Engine is removed from vehicle with transaxle attached, as an assembly.
COWL TOP VENT PANEL
- Remove windshield wiper pivot arms. Refer to PIVOT ARM - FRONT and PIVOT ARM - REAR . Remove cowl top vent panel retaining screws. Release cowl top vent panel retaining clips. Remove windshield wiper fluid hose. Remove cowl top vent panel.
- To install, reverse removal procedure.
Material
| Item | Specification |
|---|---|
| Silicone Gasket and Sealant F7AZ-19554-EA | WSE-M4G323-AA |
MATERIAL SPECIFICATION CHART
CRANKSHAFT FRONT OIL SEAL
| CAUTION | Crankshaft pulley and vibration damper are balanced together and must be installed in original location. If vibration damper is being replaced, note if original vibration damper contains balance pins. If balance pins are used, install NEW pins in same location on replacement vibration damper. |
FRONT COVER
Note. Oil pump is attached to front cover and is driven by camshaft position sensor.
CAMSHAFT
Note. It is necessary to remove engine for camshaft removal.
CMP SYNCHRONIZER
| CAUTION | A special tool and procedure are required to properly install camshaft position sensor synchronizer. Failure to do so during installation will cause fuel injection to be out of time and may cause engine damage. |
For camshaft position sensor synchronizer removal, installation and alignment procedure, see
- 1998 Windstar «REMOVE/INSTALL/OVERHAUL - 3.8L»(ref-131342) article in ENGINE PERFORMANCE
- 1999 Windstar «REMOVAL, OVERHAUL & INSTALLATION»(ref-2285) article in ENGINE PERFORMANCE
CYLINDER HEAD
Note. When valve and/or valve seat are machined, valve clearance is reduced and may cause improper valve operation. Valve lifter must be collapsed and clearance checked. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS.
| CAUTION | DO NOT machine more than .010" (.25 mm) from original cylinder head surface. |
Check cylinder head warpage. Resurface cylinder head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.
Valve Springs
- Inspect pressure of valve spring. Replace valve spring if pressure is not within specification. See «VALVES & VALVE SPRINGS»(ref-1333-S27853840032000031300000) table under ENGINE SPECIFICATIONS.
- Check springs for squareness by standing spring on table with closed end of spring downward. Hold square against spring and rotate spring. Measure space between spring and square. See «VALVES & VALVE SPRINGS»(ref-1333-S27853840032000031300000) table.
- Measure valve spring installed height from cylinder head surface to underside of spring retainer. If installed height is not within specification, install a .03" (.8 mm) shim between cylinder head and valve spring to obtain correct height. See «VALVES & VALVE SPRINGS»(ref-1333-S27853840032000031300000) table.
Valve Stem Oil Seals
Different types of valve stem oil seals are used on intake and exhaust valves. Ensure oil seal bottoms against valve guide. Oversize oil seals should be installed when using oversize valves. Exhaust valve stem oil seal can be identified by a White stripe.
Valve Guides
- Valve guides may be reamed for oversize valves if stem-to-guide oil clearance exceeds specification. See «CYLINDER HEAD»(ref-1333-S30960340402000031300000) table under ENGINE SPECIFICATIONS. Valves are available in .015" (.38 mm) and .030" (.76 mm) oversizes.
- Valve guides may also be bored and replaced with a service guide if oversize valves are not available, or if guide is damaged. Ream valve guides until proper stem-to-guide clearance exists.
Valve Seat
Ensure valve seat angle, seat width and seat runout are within specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Valve seats must be ground when valve guide is reamed or replaced. Replacement information is not available from manufacturer.
Valves
Ensure head diameter, valve face runout, stem diameter and valve margin are within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.
| CAUTION | DO NOT remove more than .010" (.25 mm) from end of valve stem when resurfacing tip of valve. |
Valve Seat Correction Angles
Use a 30-degree stone to lower seat, or a 60-degree stone to raise seat.
Fitting Pistons
- Standard selective fit pistons are color-coded Red, Blue and Yellow on piston dome. Measure piston skirt diameter at 90-degree angle to piston pin. Replace piston if not within specification. See «PISTONS, PINS & RINGS»(ref-1333-S42598483832000031300000) table under ENGINE SPECIFICATIONS.
- Measure cylinder bore 1/2" below top of cylinder bore and 1/2" above bottom of piston travel. Using bore diameter, determine color-coded piston to be used. Ensure piston-to-bore clearance is within specification. See «PISTONS, PINS & RINGS»(ref-1333-S42598483832000031300000) table.
Piston Rings
Ensure ring end gap and side clearance are within specification. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. Ensure ring gaps are NOT aligned.
Rod Bearings
- Coat rod bearings with Oil Conditioner (D9AZ-19579-CA). Coat connecting rod bolts with oil before installing nuts. Ensure piston and connecting rod are installed so dome or notch on piston's top and button on connecting rod are toward front of engine. see scheme 46
- Use plastigage method to check bearing oil clearance. Do not turn crankshaft while using plastigage. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-1333-S17468860122000031300000) and «CONNECTING RODS»(ref-1333-S34106152532000031300000) tables under ENGINE SPECIFICATIONS.
- If oil clearance exceeds specification, try using a different combination of rod bearings. See «SELECTIVE MAIN & ROD BEARINGS»(ref-1333-S14526588862000031300000) table. Use only bearing combinations listed in table.
- If any bearing cannot be adjusted to standard oil clearance specification, grind crankshaft and use undersize bearings. Ensure journal shoulder radius is reproduced when grinding journals. Shoulder radius specification is.002-.003" (.51-.76 mm) X 45 degrees.
- Upon reassembly, apply Engine Assembly Lubricant (D9AZ-19579-D) to bearing faces, ensure backside of bearing insert is free of grease. Tighten connecting rod bearing cap nuts to specification. See «TORQUE SPECIFICATIONS»(ref-1333-S08380576442000031300000).
Crankshaft & Main Bearings
- Ensure main bearing oil clearance and crankshaft end play is within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-1333-S17468860122000031300000) table under ENGINE SPECIFICATIONS. Replace thrust bearing if end play is not within specification.
- If oil clearance exceeds specification, try using a different combination of main bearings. See «SELECTIVE MAIN & ROD BEARINGS»(ref-1333-S14526588862000031300000) table. Use only bearing combinations listed in table.
- If any bearing cannot be adjusted to standard oil clearance specification, grind crankshaft and use oversize bearings. Oversize main bearings are available in .010" (.25 mm). Tighten main bearing cap bolts to specification. SELECTIVE MAIN & ROD BEARINGS Amount Of Excess Clearance - In. (mm) Use Upper Bearing - In. (mm) Use Lower Bearing - In. (mm) 0.0-.0005 (0.0-.013) .001 (.025) (1) .0005-.0010 (.013-.026) .001 (.025) .001 (.025) .0010-.0015 (.026-.039) .002 (.050) .001 (.025) .0015-.0020 (.039-.052) .002 (.050) .002 (.050) (1) Use standard bearing.
- Main bearing caps are marked for location, with No. 1 at front and No. 5 at rear of engine. Arrow on main bearing cap must point toward front of engine.
- Apply a 1/8" bead of silicone sealant to parting line between rear main bearing cap and cylinder block before installing. Install main bearing caps with arrow on cap pointing toward crankshaft pulley end of crankshaft.
- Tighten bolts finger tight. Pry crankshaft forward, and tighten main bearing cap bolts to specification. See «TORQUE SPECIFICATIONS»(ref-1333-S08380576442000031300000) . Ensure rear main bearing cap is even with rear of cylinder block.
Thrust Bearing
Thrust bearing is located on No. 3 main bearing. Replace bearing if crankshaft end play is not within specification. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.
Cylinder Block
- Using a straightedge and feeler gauge, check cylinder block head surface warpage. Machine cylinder block if warpage exceeds specification. See «CYLINDER BLOCK»(ref-1333-S07542324302000031300000) table under ENGINE SPECIFICATIONS.
- Check cylinder bore diameter, out-of-round and taper. Cylinder bore is measured 1/2" below top of cylinder block deck and 1/2" above piston when at bottom of cylinder bore. Cylinder block must be bored if measurement is not within specification. See «CYLINDER BLOCK»(ref-1333-S07542324302000031300000) table under ENGINE SPECIFICATIONS.
Oil Pressure
Oil pressure is 40-125 psi (2.8-8.8 kg/cm 2 ) at 2500 RPM with engine at normal operating temperature.