Home ReviewsRefund
Home/Ford/Windstar/Ford Windstar I (1994-2003)/Repair manual/Mechanical/Engine - 3.8L V6 - VIN [4]: Specifications
Contents Wiring diagrams Section: Mechanical All sections

Engine - 3.8L V6 - VIN [4]: Specifications Ford Windstar I

Mechanical

Crankcase Capacity

Crankcase capacity, including filter, is 4.5 qts. (4.3L).

TORQUE SPECIFICATIONS

ApplicationFt. Lbs. (N.m)
Brake Caliper Bolts26 (35)
Camshaft Sprocket Bolt33 (45)
Connecting Rod Nut
Step 115-18 (20-24)
Step 230-33 (41-45)
Step 3Additional 90-120 Degrees
Crankshaft Pulley118 (160)
Cylinder Head Bolt (1)
Step 115 (20)
Step 230 (41)
Step 337 (50)
Step 4(2) Back Off 2-3 Turns
Step 5
Long Bolt
1st Step33 (45)
2nd StepAdditional 175-185 Degrees
Short Bolt
1st Step18 (25)
2nd StepAdditional 175-185 Degrees
Engine Mount
Left Side Bolts/Nuts66 (90)
Right Side Bolts46 (63)
Right Side Nuts59-66 (80-90)
Exhaust Manifold Bolt/Nut18 (25)
Flywheel/Drive Plate Bolt (3)59 (80)
Front Cover Bolt18 (25)
Main Bearing Cap Bolt/Stud
Step 137 (50)
Step 2Additional 115-125 Degrees
Oil Filter Adapter Bolt18-22 (24-30)
Oil Pick-Up Tube Bolt/Nut
At Cylinder Block18 (25)
At Main Bearing Cap35 (48)
Oil Pan Baffle Bolt35 (48)
Oil Pump Bolt
Large Bolt18-22 (24-30)
Small Bolt(4)
Power Steering Bracket Bolt35 (48)
Rocker Arm Bolt(5)
Stabilizer Bar Nuts70 (95)
Steering Shaft Pinch Bolt36 (48)
Strut Mount Bolts91 (124)
Subframe Bolt66 (90)
Throttle Body Nut18 (25)
Torque Converter Nut27 (36)
Transaxle-To-Cylinder Block Bolt30 (40)
Water Pump Bolt18 (25)
INCH Lbs. (N.m)
Balance Shaft Thrust Plate Bolt89 (10)
Camshaft Thrust Plate Bolt71-124 (8-14)
Cylinder Head Studs71 (8)
Fuel Rail Bolt89 (10)
Intake Manifold Spacer Bolt (6)89 (10)
Lower Intake Manifold Bolt (6)
Step 145 (5)
Step 289 (10)
Oil Pan Bolt89 (10)
Timing Chain Vibration Damper Bolt71-124 (8-14)
Upper Intake Manifold Bolt (6)
Step 144 (5)
Step 289 (10)
Valve Cover Bolt89 (10)
(1) Use NEW cylinder head bolts. Apply sealant to shortest bolts. Tighten bolts in sequence. (Схема №41) (2) DO NOT loosen all bolts at one time. Work on one bolt at a time. (3) Apply thread sealant to bolt threads. (4) Tighten bolts to 72-96 INCH lbs. (8-11 N.m). (5) Tighten bolt to 43 INCH lbs. (5 N.m) with valve lifter on base circle of camshaft. Once all rocker arms are tightened, retighten bolts to 19-25 ft. lbs. (26-34 N.m). (6) Tighten bolts in sequence.
(1)Use NEW cylinder head bolts. Apply sealant to shortest bolts. Tighten bolts in sequence. (Схема №41)
(2)DO NOT loosen all bolts at one time. Work on one bolt at a time.
(3)Apply thread sealant to bolt threads.
(4)Tighten bolts to 72-96 INCH lbs. (8-11 N.m).
(5)Tighten bolt to 43 INCH lbs. (5 N.m) with valve lifter on base circle of camshaft. Once all rocker arms are tightened, retighten bolts to 19-25 ft. lbs. (26-34 N.m).
(6)Tighten bolts in sequence.

TORQUE SPECIFICATIONS

GENERAL SPECIFICATIONS

ApplicationSpecification
Displacement232 Cu. In. (3.8L)
Bore3.81" (96.8 mm)
Stroke3.39" (86.1 mm)
Compression Ratio9.0:1
Fuel SystemSFI

GENERAL SPECIFICATIONS

CRANKSHAFT, MAIN BEARINGS & CONNECTING ROD BEARINGS SPECIFICATIONS

ApplicationIn. (mm)
Crankshaft End Play.004-.008 (.10-.20)
Main Bearings
Journal Diameter2.5190-2.5198 (63.983-64.003)
Journal Out-Of-Round.0003 (.008)
Journal Taper.0003 Per 1 (.008 Per 25.4)
Oil Clearance
Standard.0010-.0014 (.025-.036)
Service Limit.0023 (.058)
Connecting Rod Bearings
Journal Diameter2.3103-2.3111 (58.682-58.702)
Journal Out-Of-Round.0003 (.008)
Journal Taper.0003 Per 1 (.008 Per 25.4)
Oil Clearance
Standard.0010-.0014 (.025-.036)
Service Limit.0027 (.069)

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CONNECTING RODS SPECIFICATIONS

ApplicationIn. (mm)
Bore Diameter
Pin Bore.90315-.90472 (22.94-22.98)
Crankpin Bore2.4266-2.4274 (61.636-61.656)
Center-To-Center Length6.089-6.092 (154.66-154.74)
Maximum Bend.0016 Per 1 (.041 Per 25.4)
Maximum Twist.002 Per 1 (.06 Per 25.4)
Side Play
Standard.0047-.0192 (.119-.490)
Service Limit.014 (.36)

CONNECTING RODS

ENGINE PISTONS, PISTON PINS & PISTON RINGS SPECIFICATIONS

ApplicationIn. (mm)
Pistons
Piston Clearance.0007-.0017 (.018-.043)
Diameter (1)
Red3.8103-3.8108 (96.782-96.794)
Blue3.8108-3.8113 (96.794-96.807)
Yellow3.8113-3.8118 (96.807-96.820)
Pins
Diameter.9060-.9062 (23.014-23.018)
Piston Fit.0004-.0007 (.010-.018)
Rod Fit(2)
Rings
No. 1
End Gap.0067-.013 (.17-.33)
Side Clearance.0011-.0031 (.030-.080)
No. 2
End Gap.011-.021 (.30-.55)
Side Clearance.0018-.0031 (.030-.080)
No. 3 (Oil)
End Gap.006-.026 (.15-.66)
(1) Piston diameter is determined by color code on dome of piston. (2) Press fit with load of 1800 lbs. (816 kg).
(1)Piston diameter is determined by color code on dome of piston.
(2)Press fit with load of 1800 lbs. (816 kg).

PISTONS, PINS & RINGS

CYLINDER BLOCK SPECIFICATIONS

ApplicationIn. (mm)
Cylinder Bore
Standard Diameter3.81 (96.8)
Maximum Taper.002 (.05)
Maximum Out-Of-Round.002 (.05)
Maximum Deck Warpage(1) .003 Per 6 (.08 Per 152)
Balance Shaft Bore I.D.2.191-2.192 (55.651-55.677)
Camshaft Bearing I.D.2.0525-2.0535 (52.134-52.159)
Camshaft Bearing Bore I.D.
No. 1 & 42.191-2.192 (55.651-55.677)
No. 2 & 32.176-2.177 (55.270-55.296)
Main Bearing Bore2.712-2.713 (68.88-68.91)
(1) DO NOT machine more than .010" (.25 mm) from original cylinder block deck surface.
(1)DO NOT machine more than .010" (.25 mm) from original cylinder block deck surface.

CYLINDER BLOCK

ENGINE VALVES & VALVE SPRINGS SPECIFICATIONS

ApplicationSpecification
Intake Valves
Face Angle45.675°
Head Diameter1.86" (47.27 mm)
Minimum Margin.031" (.79 mm)
Stem Diameter.2738-.2751" (6.955-6.988 mm)
Valve Face Runout.002" (.05 mm)
Exhaust Valves
Face Angle45.675°
Head Diameter1.46" (37.1 mm)
Minimum Margin.031" (.79 mm)
Stem Diameter.2728-.2741" (6.929-6.962 mm)
Valve Face Runout.002" (.05 mm)
Valve Springs
Installed Height1.62" (40.7 mm)
Lbs. @ In. (kg @ mm)
Pressure
Valve Closed79 @ 1.62 (35.8 @ 40.7)
Valve Open224 @ 1.16 (101 @ 29.2)

VALVES & VALVE SPRINGS

VALVE LIFTERS SPECIFICATIONS

ApplicationIn. (mm)
Lifter Diameter.8740-.8745 (22.200-22.212)
Oil Clearance
Standard.0007-.0027 (.018-.069)
Service Limit.005 (.13)

VALVE LIFTERS

CYLINDER HEAD SPECIFICATIONS

ApplicationSpecification
Maximum Warpage(1) .007" (.18 mm)
Valve Seats
Intake Valve
Seat Angle44.75°
Seat Width.06-.08" (1.5-2.0 mm)
Maximum Seat Runout.003" (.08 mm)
Exhaust Valve
Seat Angle44.75°
Seat Width.06-.08" (1.5-2.0 mm)
Maximum Seat Runout.003" (.08 mm)
Valve Guides
Valve Guide I.D..276-.277" (7.015-7.044 mm)
Valve Stem-To-Guide Oil Clearance
Intake Valve.045-.090" (.020-.070 mm)
Exhaust Valve.0017-.0037" (.045-.095 mm)
(1) DO NOT machine more than .010" (.25 mm) from original cylinder head surface.
(1)DO NOT machine more than .010" (.25 mm) from original cylinder head surface.

CYLINDER HEAD

CAMSHAFT SPECIFICATIONS

ApplicationIn. (mm)
Camshaft Bearing I.D.2.0525-2.0535 (52.134-52.159)
End Play.001-.006 (.0255-.152)
Journal Diameter2.067-2.075 (52.502-52.704)
Lobe Lift (1)
Intake.257 (6.53)
Exhaust.259 (6.58)
Oil Clearance.001-.003 (.03-.08)
(1) Maximum allowable lobe-lift loss is .005" (.13 mm).
(1)Maximum allowable lobe-lift loss is .005" (.13 mm).

CAMSHAFT

More articles — Engine - 3.8L V6 - VIN [4]