Engine - 3.8L V6 - VIN [4]: Removal & Installation Ford Windstar I

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Place mating marks on engine hood and other major assemblies before removal.

Removal

1. Disconnect negative battery cable. Drain cooling system. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove cowl top vent panel. Disconnect generator voltage regulator wiring. Remove air cleaner assembly.
2. Remove upper radiator hose. Remove heater hoses and bracket. Disconnect A/C suction and discharge hoses at accumulator and plug openings. Disconnect control cables from throttle body. Remove accelerator cable bracket.
3. Release fuel pressure, and disconnect fuel lines. See «FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS»(ref-1333-S26841337642000031300000) . Mark and disconnect wiring harness connectors and vacuum hoses as necessary. Disconnect ground straps. Disconnect shift cable from transaxle. CAUTION: Damage to steering column air bag wiring can result from allowing steering wheel to rotate too far in either direction. Lock steering wheel in straight-ahead position.
4. Raise vehicle on hoist. Drain engine oil, and remove oil filter. Remove wheel assemblies. Disconnect transaxle cooler lines using Oil Cooler Line Disconnect Tool (T86P-77265-AH). Disconnect oxygen sensors. Remove dual-converter crossover pipe bolts. Remove dual-converter crossover pipe using Exhaust Connector Holder (T94T-6000-AH).
5. Disconnect starter motor wiring. Remove torque converter nuts. Disconnect power steering fluid cooler lines. Remove lower radiator hose. Remove auxiliary heater hose (if equipped). Remove steering gear pinch bolt. Separate steering shaft from steering gear.
6. Remove right and left stabilizer bar links. Disconnect lower ball joints and tie rods from steering knuckle. Remove both axle shafts. Support front sub-frame, engine and transaxle assembly with Rotunda Powertrain Lift (014-00765) and Adapter (014-00341). Remove 4 front sub-frame bolts.
7. Disconnect power steering pressure hose. Lower engine, transaxle and front sub-frame assembly from vehicle. Separate sub-frame from engine and transaxle assembly. Disassemble as necessary.

Installation

1. To install, reverse removal procedure. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-1333-S33710971152000031300000) table.
2. When installing fuel lines, install NEW "O" rings on fuel lines. Use only specified fuel resistant "O" rings (Brown). Lightly coat with clean engine oil before installing. Clean fittings, and replace garter spring (if necessary).
3. Adjust control cables and fluid levels. Refill cooling system. Evacuate and recharge A/C system. Check wheel alignment. See «SPECIFICATIONS & PROCEDURES - TRUCKS»(ref-1219) article in WHEEL ALIGNMENT.

Removal and Installation

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1. Remove cowl top vent panel. Refer to «COWL TOP VENT PANEL»(ref-1333-S26276084552012032000000) .
2. Remove the air cleaner outlet pipe.
3. Remove the idle air control (IAC) valve. Disconnect the IAC valve electrical connector. Remove the two bolts and the IAC valve.
4. Remove the fuel line retaining clip and the wire harness pin-type retainers.
5. Remove the alternator wire harness retaining clips.
6. Position the spark plug wires aside. Lift the spark plug wire separators. Position the spark plug wires aside.
7. Remove the upper intake manifold. Remove the stud bolts. Remove the bolts. Remove the cover.
8. Disconnect the accelerator and speed control cables, then remove the throttle return spring.
9. Position the bracket aside. Remove the bolt. Remove the stud bolt. Position the bracket aside.
10. Disconnect the throttle position (TP) sensor electrical connector.
11. Disconnect the evaporative emissions return tube.
12. Disconnect the brake booster vacuum hose.
13. Disconnect the exhaust gas recirculation (EGR) vacuum regulator solenoid electrical and vacuum connections.
14. Disconnect the vacuum hose.
15. Disconnect the fuel pressure regulator vacuum tube.
16. Disconnect the positive crankcase ventilation (PCV) hose.
17. Remove the upper intake manifold spacer. Remove the bolts. Remove the intake manifold spacer.
18. To install, reverse the removal procedure. Tighten the upper intake manifold spacer and upper intake manifold in the sequences shown.

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Scheme 49

1. Drain the cooling system. Refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
2. Remove the upper intake manifold. Refer to INTAKE MANIFOLD - UPPER .
3. Remove the fuel supply manifold. Refer to FUEL INJECTION SUPPLY MANIFOLD & INJECTORS .
4. Disconnect the EGR vacuum tube.
5. Disconnect the EGR-to-exhaust manifold tube. Loosen the nut.
6. Disconnect the heater hose. Compress the fitting. Disconnect the hose.
7. Disconnect the upper radiator hose. Reposition the clamp. Disconnect the hose.
8. Disconnect the intake manifold runner control (IMRC).
9. Position the water bypass tube aside. Remove the bolts. Position the tube aside.
10. Remove the lower intake manifold. Remove the bolts. Remove the intake manifold.
11. Remove the intake manifold runner control (IMRC) if necessary. Refer to INTAKE MANIFOLD RUNNER CONTROL ACTUATOR .
12. Remove and discard the lower intake manifold sealing components.

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Scheme 61

1. Refer to the illustration for intake manifold sealing component locations.
2. Install the lower intake manifold front and rear end seals. Apply a bead of sealant to the intake manifold front and rear end seal mounting points as indicated. Install the lower intake manifold front and rear end seals.
3. Install the intake manifold gaskets (9439).
4. Install the intake manifold runner control (IMRC) if required. Refer to INTAKE MANIFOLD RUNNER CONTROL ACTUATOR .
5. Position the lower intake manifold. Apply a bead of sealant to the lower intake manifold mounting at the points indicated. Position the lower intake manifold.
6. Install the six long bolts.
7. Install the eight short bolts.
8. Make sure to tighten the bolts in two stages following the sequence shown. Stage 1: Tighten to 5 N.m (44 lb-in). Stage 2: Tighten to 10 N.m (89 lb-in).
9. Connect the water bypass tube. Position the tube. Install the bolts.
10. Connect the intake manifold runner control (IMRC) electrical connector.
11. Connect the upper radiator hose. Connect the hose. Position the clamp.
12. Connect the heater hose.
13. Connect the EGR to exhaust manifold tube. Tighten the nut.
14. Connect the EGR vacuum tube.
15. Install the fuel supply manifold. Refer to FUEL INJECTION SUPPLY MANIFOLD & INJECTORS .
16. Install the upper intake manifold. Refer to INTAKE MANIFOLD - UPPER .
17. Fill and bleed the cooling system. Refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .

Removal (Left Manifold)

Remove oil dipstick tube support bracket. Disconnect spark plug wires from spark plugs. Disconnect EGR manifold tube. Raise and support vehicle. Separate exhaust pipe from exhaust manifold. Lower vehicle. Remove retaining bolts in reverse order of tightening sequence. (Scheme 64) Remove exhaust manifold.

1. To install, reverse removal procedure. Lightly oil all bolt and stud threads before installing. A slight warpage, causing misalignment, may be corrected by elongating bolt holes as necessary. DO NOT elongate lower front bolt hole on cylinder No. 5.
2. Tighten bolts to specification. (Scheme 64) See «TORQUE SPECIFICATIONS»(ref-1333-S33710971152000031300000) table. If oxygen sensor is removed, apply anti-seize to threads before installing. DO NOT allow anti-seize to contact any area except threads of oxygen sensor.

Removal (Right Manifold)

1. Remove top vent cowl. Remove air cleaner assembly and heat tube. Remove coil wire and plug wires from spark plugs. Remove spark plugs.
2. Raise and support vehicle. Separate exhaust pipe from exhaust manifold. Lower vehicle. Remove retaining bolts in reverse order of tightening sequence. (Scheme 64) Remove exhaust manifold.

To install, reverse removal procedure. Lightly oil all bolt and stud threads before installing. A slight warpage, causing misalignment, may be corrected by elongating bolt holes as necessary. DO NOT elongate lower rear bolt hole on cylinder No. 2. Tighten bolts to specification. (Scheme 64) See TORQUE SPECIFICATIONS table.

Scheme 62

1. Disconnect negative battery cable. Drain cooling system. Remove air inlet tube between throttle body and air cleaner assembly. Remove accessory drive belt. Remove upper and lower intake manifolds. See «INTAKE MANIFOLD»(ref-1333-S41337696332000031300000) .
2. If removing left cylinder head, remove power steering pump, generator and generator idler pulley. If removing right cylinder head, unbolt A/C compressor and set aside with hoses attached.
3. Remove valve covers. Loosen rocker arm bolts, and pivot rocker arms from push rods. Mark component location for reassembly reference. Remove and discard cylinder head bolts, noting location of different size bolts for installation. DO NOT reuse bolts. Remove cylinder head and gasket.

1. Ensure bolt holes in cylinder block are clean. Install gasket and cylinder head. Apply a thin coat of Teflon Pipe Sealant (D8AZ-19554-A) to threads of new short cylinder head bolts (closest to exhaust manifold). Lubricate all other bolts with light coat of engine oil. DO NOT apply sealant to long cylinder head bolts.
2. Install NEW cylinder head bolts. Tighten cylinder head bolts to specification in sequence. (Scheme 65) See «TORQUE SPECIFICATIONS»(ref-1333-S33710971152000031300000) table.
3. Coat ends of push rods with Engine Assembly Lubricant (D9AZ-19579-D) and install in original position. Before installing rocker arm on push rod, rotate crankshaft until push rod is fully downward, and valve lifter is on base circle of camshaft. Position rocker arm on push rod, and tighten bolt to 43 INCH lbs. (5 N.m).
4. Repeat procedure for remaining push rods and rocker arms. Tighten rocker arm bolt to final specification. See «TORQUE SPECIFICATIONS»(ref-1333-S33710971152000031300000) table. Final tightening of rocker arms may be done with camshaft in any position. NOTE: If cylinder head or valve train components are serviced, check valve clearance adjustment. See «VALVE CLEARANCE ADJUSTMENTS»(ref-1333-S41708953422000031300000) under ADJUSTMENTS.
5. To complete installation, reverse removal procedure. Tighten all bolts and nuts to specification. Refill cooling system.

Remove accessory drive belts. Place reference mark on crankshaft pulley and vibration damper. Remove vibration damper retaining bolt. Using Vibration Damper Remover (T58P-6316-D) and Adapter (T82L-6316-B), remove vibration damper. Using screwdriver, pry seal from front cover.

1. Lubricate seal and sealing surfaces with engine oil. Using Seal Installer (T82L-6316-A and T70P-6B070-A), install seal.
2. Coat seal surface of vibration damper with engine oil. Using Vibration Damper Installer (T82L-6316-A), install vibration damper.
3. To complete installation, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-1333-S33710971152000031300000) table. Ensure reference marks align on crankshaft pulley and vibration damper.

1. Remove engine from vehicle. See «ENGINE»(ref-1333-S29636079452000031300000) . Loosen drive belt tensioner and remove drive belt. Remove water pump pulley. Disconnect lower radiator and heater hose from water pump. Rotate crankshaft to position piston No. 1 at TDC (compression stroke).
2. Note location of Camshaft Position (CMP) sensor assembly connector for installation reference, and disconnect connector. Remove CMP sensor assembly.
3. Remove camshaft position synchronizer housing retaining bolt. Remove synchronizer housing along with intermediate shaft. Disconnect crankshaft position sensor connector.
4. Using Vibration Damper Remover (T58P-6316-D) and Adapter (T82L-6316-B), remove crankshaft pulley and vibration damper. Remove oil pan. See «OIL PAN»(ref-1333-S08900380252000031300000) . Remove front cover bolts. Two front cover bolts are behind oil filter mounting flange. Remove front cover and water pump as an assembly. Remove gasket. Clean gasket surfaces.

1. Lightly oil threads of bolt and stud before installing, except those requiring thread sealant. Use Gasket & Trim Adhesive (D7AZ-19B5O8-B) to hold front cover gasket in place on cylinder block.
2. Coat crankshaft front seal lip with engine oil. Install front cover and water pump as an assembly. Install front cover bolts. Apply Loctite to bolt closest to oil filter mounting flange and tighten this bolt last. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-1333-S33710971152000031300000) table.
3. Coat seal surface of vibration damper with engine oil. Using Vibration Damper Installer (T82L-6316-A), install vibration damper.
4. 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
5. To install remaining components, reverse removal procedure. Ensure reference marks on crankshaft pulley and vibration damper align. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-1333-S33710971152000031300000) table. Refill cooling system.

1. Remove front cover. See «FRONT COVER»(ref-1333-S12096625892000031300000). Ensure timing marks on all gears align. see scheme 43 Remove retaining bolt, and remove synchronizer assembly drive gear.
2. Remove camshaft gear, crankshaft gear and timing chain. (Scheme 66) If crankshaft gear is difficult to remove, position a pair of screwdrivers evenly on gear and carefully pry it off.
3. Remove tensioner/snubber assembly by pulling back on ratcheting mechanism and installing a pin through hole in bracket. Remove retaining bolts, and remove tensioner/snubber assembly. (Scheme 66)

Scheme 63

1. Lightly oil threads of bolts and studs. Ensure crankshaft key is at 12 o'clock position. Install tensioner/snubber assembly with ratcheting mechanism in retracted position and pin in bracket hole facing outward.
2. Install crankshaft gear, camshaft gear and timing chain as an assembly. Ensure timing marks and keyways align. see scheme 43 With all timing marks aligned, remove pin from tensioner/snubber assembly to apply tension to timing chain.
3. Install front cover. See «FRONT COVER»(ref-1333-S12096625892000031300000).
4. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-1333-S33710971152000031300000) table. To install remaining components, reverse removal procedure.

Scheme 64

1. Remove upper and lower intake manifolds. See «INTAKE MANIFOLD»(ref-1333-S41337696332000031300000). Remove valve covers. Loosen rocker arm bolts, and pivot rocker arms from push rods.
2. Mark push rod location, and remove push rods. Remove guide plate retainers. see scheme 44 Remove guide plate. Mark valve lifter location for reassembly reference. Remove valve lifters.

Scheme 65

1. Lubricate valve lifter and cylinder block bore with Assembly Lubricant (D9AZ-19579-D) or heavy engine oil. Install valve lifter in original location.
2. Align flat sides of valve lifters, and install guide plates with the word UP showing. Install guide plate retainer. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-1333-S33710971152000031300000) table.
3. Coat push rods with Assembly Lubricant (D9AZ-19579-D) and install in original position. Before installing rocker arm on push rod, rotate crankshaft until push rod is fully downward and valve lifter is on base circle of camshaft. Position rocker arm on push rod, and tighten bolt to 43 INCH lbs. (5 N.m).
4. Repeat procedure for remaining push rods and rocker arms. Tighten all rocker arms to specification. Final tightening of rocker arms may be done with camshaft in any position. To install remaining components, reverse removal procedure.

1. Remove upper intake manifold, upper intake manifold spacer and lower intake manifold. See «INTAKE MANIFOLD»(ref-1333-S41337696332000031300000) . Remove valve lifters. See «VALVE LIFTER»(ref-1333-S04810685882000031300000) .
2. Remove engine front cover and timing chain. See «FRONT COVER»(ref-1333-S12096625892000031300000) and «TIMING CHAIN»(ref-1333-S29634591122000031300000) . Remove oil pan. See «OIL PAN»(ref-1333-S08900380252000031300000) . Remove camshaft. DO NOT damage camshaft bearing surfaces.

1. To install, reverse removal procedure. Ensure oil holes in camshaft bearings and cylinder block align. Apply sealant to rear camshaft bore plug before installing. NOTE: Oversize rear camshaft bore plug can be identified by oversize stamped on flat area of plug. Ensure proper size plug is installed.
2. Lubricate camshaft lobes and bearing surfaces with Assembly Lubricant (D9AZ-19579-C). Install camshaft. Tighten thrust plate bolts to specification. See «TORQUE SPECIFICATIONS»(ref-1333-S33710971152000031300000) table.
3. Ensure camshaft end play is within specification. See «CAMSHAFT»(ref-1333-S26233067312000031300000) table under ENGINE SPECIFICATIONS. To complete installation, reverse removal procedure. Refill cooling system.

1. Remove engine. See «ENGINE»(ref-1333-S29636079452000031300000). Remove timing chain and gears. See «TIMING CHAIN»(ref-1333-S29634591122000031300000).
2. Remove balance shaft drive gear from camshaft. Remove balance shaft thrust plate bolts. Remove balance shaft. see scheme 45
3. If replacing balance shaft bearings, remove rear bore plug. Use Camshaft/Balance Shaft Bearing Set (T65L-6250-A) to remove balance shaft bearings.

Scheme 66

1. To install, reverse removal procedure. Lubricate all components with engine oil before installation. Apply sealant to rear bore plug before installing. NOTE: Oversize rear bore plug can be identified by oversize stamped on flat area of plug. Ensure proper size plug is installed.
2. Ensure all timing marks align. see scheme 43 Check balance shaft end play. Replace thrust plate if end play is not within specification. See «BALANCE SHAFT SPECIFICATIONS»(ref-1333-S16928798062000031300000) table.

Rear main bearing oil seal is a one-piece seal. Remove transaxle. See appropriate TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. Remove flexplate/flywheel. Punch hole in metal portion of seal with an awl. Remove seal with a slide hammer.

1. Lubricate seal and mating surfaces with engine oil. Install seal on crankshaft with spring side toward crankshaft. Using Seal Installer (T82L-6701-A), install seal so rear face of seal is within .005" (.13 mm) of rear surface of cylinder block.
2. To install remaining components, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-1333-S08380576442000031300000) . CAUTION: Apply thread sealant on threads of drive plate or flywheel bolts before installing.

1. Disconnect negative battery cable. Drain cooling system. Remove accessory drive belt. Raise and support vehicle. Remove lower radiator hose. Remove nut on both front engine mounts. Lower vehicle. Remove alternator. Disconnect power steering pump pressure hose. Remove cowl extension panel.
2. Disconnect heater outlet tube from water pump. Remove A/C compressor front bracket, leaving compressor in place (if equipped). Attach lifting equipment to left exhaust manifold. Raise engine approximately 5" (127 mm). Remove water pump bolts and nuts. Remove drive belt tensioner pulley.
3. Remove power steering pump with hose attached and position aside. Remove water pump and gasket.

1. Install gasket using Gasket & Trim Adhesive (D7AZ-19B508-B). To complete installation, reverse removal procedure. Lightly oil threads of bolt and stud not containing thread sealant.
2. If bolts originally contained thread sealant, clean and reapply thread sealant to bolts. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-1333-S08380576442000031300000) . Fill cooling system.

1. Disconnect negative battery cable. Raise and support vehicle. Drain engine oil, and remove oil filter.
2. Remove exhaust pipe assembly located below oil pan. Remove starter and torque converter housing cover. Remove retaining bolts, oil pan and seals.

To install, reverse removal procedure. Before installing oil pan, apply Silicone Sealant (E3AZ-19652-A) on oil pan rails of cylinder block, rear main bearing cap and front cover-to-cylinder block areas. Tighten oil pan bolts to specification. See TORQUE SPECIFICATIONS . Fill engine with oil.

Removal & Disassembly

Oil pump is bolted to front cover. Remove oil filter and oil cooler (if equipped). Remove oil pump-to-front cover bolts, and remove oil pump. Disassemble oil pump. Note direction of component installation.

Reassembly & Installation

1. To reassemble, reverse disassembly procedure. Ensure components are installed in original location. Lubricate components thoroughly.
2. Tighten oil pump cover bolts to specification. See «TORQUE SPECIFICATIONS»(ref-1333-S08380576442000031300000) . To install, reverse removal procedure. Tighten bolts to specification.