Windstar 2000-2001 3.8 v6

2000-01 ENGINES 3.
8L V6 - VIN 4 - Windstar
Engine may be identified by eighth character of Vehicle Identification Number (VIN). See ENGINE
IDENTIFICATION CODES table. VIN is located on top of instrument panel, near lower left corner of
windshield.
An emission calibration number is located on driver's door or door-post pillar. This label identifies engine
calibration number, engine code and revision label.
Engine code label is located on valve cover. Label contains engine calibration number, engine build date, plant
code and engine code. Information from labels are required when ordering replacement parts.
ENGINE IDENTIFICATION CODES

Engine Code
3.8L SFI 4
VALVE CLEARANCE ADJUSTMENT
1. With valve cover removed, position piston No. 1 at TDC of compression stroke. Completely collapse
cylinder No. 1 intake valve lifter and hold valve lifter collapsed. Using feeler gauge, measure clearance
between rocker arm and valve stem.
2. Clearance should be within specification. See COLLAPSED VALVE LIFTER CLEARANCE table.
Replace push rod, if necessary, to obtain correct clearance.
3. Position crankshaft as specified in VALVE CLEARANCE CHECKING SEQUENCE table, and check
appropriate valves. Replace push rods if clearance is not within specification.
4. If push rod(s) is replaced, ensure corresponding cylinder piston is below TDC. It will be necessary to
loosen or remove rocker arm to replace push rod.
COLLAPSED VALVE LIFTER CLEARANCE
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07:42:13 p. m. Page 1 © 2011 Mitchell Repair Information Company, LLC.
2000-01 ENGINES 3.8L V6 - VIN 4 - Windstar
Application In. (mm)

Intake & Exhaust .09-.19 (2.3-4.8)
VALVE CLEARANCE CHECKING SEQUENCE

Crankshaft Position (1) Intake Valves Exhaust Valves
No. 1 Cylinder At TDC No. 1, 3 & 6 No. 1, 2 & 4
Rotate 360° No. 2, 4 & 5 No. 3, 5 & 6
(1) Begin with cylinder No. 1 at TDC of compression stroke. Check corresponding valves clearance,
rotate crankshaft 360 degrees, and recheck clearance of corresponding valves.
FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS
1. 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.
2. 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. See Fig. 1.
3. Push spring lock coupling remover into cage opening to release female fitting from garter spring. Pull
couplings apart. Remove spring lock coupling remover.
4. When installing fuel lines, install NEW "O" rings on fuel lines. Use only specified Brown fuel resistant
"O" rings. 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.
martes, 9 de junio de 2020 07:42:13 p. m. Page 2 © 2011 Mitchell Repair Information Company, LLC.
5. 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.
Fig. 1: Disconnecting Fuel Lines

Courtesy of FORD MOTOR CO.
ENGINE
Removal
1. Remove cowl top vent panel. See COWL TOP VENT PANEL. Disconnect negative battery cable.
Drain cooling system. Discharge A/C system using approved refrigerant recovery/recycling equipment.
Release fuel pressure, and disconnect fuel lines. See FUEL PRESSURE RELEASE & FUEL LINE
CONNECTIONS. Remove cowl top vent panel. Remove air cleaner assembly.
2. Disconnect control cables from throttle body. Remove accelerator cable bracket bolt, and position
accelerator cable bracket aside. Disconnect heater hose. Disconnect upper radiator hose. Remove heater
hose bracket retaining nut, and position heater hose and bracket aside. Loosen main engine wiring harness
retaining bolt, and disconnect main engine wiring harness connector. Disconnect shift cable from
transaxle, and cable from bracket, position shift cable aside.
3. Disconnect EVAP emission return tube, and brake booster vacuum hose. Disconnect EVAP canister
purge valve electrical connector and vacuum tube. Remove wiring harness pin-type retainer. Disconnect
Powertrain Control Module. Disconnect main engine wiring harness ground cable.
4. Disconnect power steering hose. Disconnect degas bottle hose. Disconnect generator. Remove auxiliary
heater hose (if equipped). Remove sight shield. Remove A/C suction/discharge manifold retaining bolt,
and position aside. Disconnect power steering fluid cooler lines. Disconnect transaxle cooler lines Mark
and disconnect wiring harness and vacuum hoses as necessary.
5. Remove steering gear pinch bolt. Separate steering shaft from steering gear. Raise vehicle on hoist. Drain
engine oil, and remove oil filter. Remove wheel assemblies. Disconnect oxygen sensors. Remove dual-
converter crossover pipe bolts. Remove dual-converter crossover pipe. Disconnect lower radiator hose.
6. Remove brake caliper retaining bolts, and position calipers aside. Remove ABS wiring harness retainer,
and disconnect ABS electrical connector.
7. Remove right and left side stabilizer bar links. Remove right and left side strut bolts. Support front
subframe, engine and transaxle assembly with Rotunda Powertrain Lift (014-00765) and Adapter (014-
00341). Remove 4 front subframe bolts. Lower engine, transaxle and subframe assembly. Remove starter
motor. Remove inspection cover bolt, and remove inspection cover. Remove 4 torque converter nuts.
Disconnect transaxle electrical connectors.
8. Disconnect power steering pressure hose. Remove transaxle oil level dipstick and tube. Install Engine
Lifting Bracket Set (D94L-6001-A) onto right and left side of engine. Remove 6 bell housing bolts.
Remove left engine mount bolts. Remove right engine mount nut. Remove 2 mount bolts located above
axle shaft. Separate engine from subframe and transaxle assembly. Disassemble as necessary.
Installation
1. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE
SPECIFICATIONS.
2. When installing fuel lines, install NEW "O" rings on fuel lines. Use only specified Brown fuel resistant
"O" rings. 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 appropriate SPECIFICATIONS & PROCEDURES article in WHEEL
ALIGNMENT.
COWL TOP VENT PANEL
1. 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.
2. To install, reverse removal procedure.
INTAKE MANIFOLD
Intake Manifold - Upper
Removal and Installation
1. Remove cowl top vent panel. Refer to COWL TOP VENT PANEL.
2. Remove the air cleaner outlet pipe.
3. Remove the idle air control (IAC) valve.
l Disconnect the IAC valve electrical connector.
l Remove the two bolts and the IAC valve.
Fig. 2: Removing Bolts And IAC Valve
Fig. 3: Removing Fuel Line Retaining Clip

4. Remove the fuel line retaining clip and the wire harness pin-type retainers.
5. Remove the alternator wire harness retaining clips.
Fig. 4: Removing Alternator Wire Harness Retaining Clips

6. Position the spark plug wires aside.

l Lift the spark plug wire separators.
l Position the spark plug wires aside.
Fig. 5: Identifying Position Spark Plug Wires Aside

7. Remove the upper intake manifold.

1. Remove the stud bolts.
2. Remove the bolts.
3. Remove the cover.
Fig. 6: Removing Upper Intake Manifold

8. Disconnect the accelerator and speed control cables, then remove the throttle return spring.
Fig. 7: Disconnecting Accelerator And Speed Control Cables

9. Position the bracket aside.

l Remove the bolt.
l Remove the stud bolt.
l Position the bracket aside.
Fig. 8: Identifying Bracket Bolts

10. Disconnect the throttle position (TP) sensor electrical connector.
Fig. 9: Disconnecting Throttle Position (TP) Sensor Electrical Connector

11. Disconnect the evaporative emissions return tube.
Fig. 10: Disconnecting Evaporative Emissions Return Tube

12. Disconnect the brake booster vacuum hose.
Fig. 11: Disconnecting Brake Booster Vacuum Hose

13. Disconnect the exhaust gas recirculation (EGR) vacuum regulator solenoid electrical and vacuum
connections.
Fig. 12: Disconnecting Exhaust Gas Recirculation (EGR) Vacuum Regulator Solenoid Electrical
14. Disconnect the vacuum hose.
Fig. 13: Disconnecting Vacuum Hose

15. Disconnect the fuel pressure regulator vacuum tube.
Fig. 14: Disconnecting Fuel Pressure Regulator Vacuum Tube

16. Disconnect the positive crankcase ventilation (PCV) hose.
Fig. 15: Disconnecting Positive Crankcase Ventilation (PCV) Hose

17. Remove the upper intake manifold spacer.

l Remove the bolts.
l Remove the intake manifold spacer.
Fig. 16: Removing Upper Intake Manifold Spacer

18. To install, reverse the removal procedure.

l Tighten the upper intake manifold spacer and upper intake manifold in the sequences shown.
Fig. 17: Tightening Upper Intake Manifold Spacer

Fig. 18: Tightening Upper Intake Manifold

Intake Manifold - Lower
Material
MATERIAL SPECIFICATION CHART

Item Specification
Silicone Gasket and Sealant WSE-M4G323-AA
F7AZ-19554-EA
Removal
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.
Fig. 19: Disconnecting EGR Vacuum Tube

5. Disconnect the EGR-to-exhaust manifold tube.

l Loosen the nut.
Fig. 20: Disconnecting EGR-To-Exhaust Manifold Tube

6. Disconnect the heater hose.

l Compress the fitting.
l Disconnect the hose.
Fig. 21: Disconnecting Heater Hose

7. Disconnect the upper radiator hose.

l Reposition the clamp.
l Disconnect the hose.
Fig. 22: Disconnecting Upper Radiator Hose

8. Disconnect the intake manifold runner control (IMRC).
Fig. 23: Disconnecting Intake Manifold Runner Control (IMRC)

9. Position the water bypass tube aside.

2. Position the tube aside.
Fig. 24: Positioning Water Bypass Tube Aside

10. Remove the lower intake manifold.

2. Remove the intake manifold.
Fig. 25: Removing Lower 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.
Fig. 26: Removing Lower Intake Manifold Sealing Components

Installation
1. Refer to the illustration for intake manifold sealing component locations.
Fig. 27: Identifying Intake Manifold Sealing Component Locations

2. Install the lower intake manifold front and rear end seals.
1. Apply a bead of sealant to the intake manifold front and rear end seal mounting points as indicated.
2. Install the lower intake manifold front and rear end seals.
Fig. 28: Installing Lower Intake Manifold Front And Rear End Seals
3. Install the intake manifold gaskets (9439).
Fig. 29: Installing Intake Manifold Gaskets

4. Install the intake manifold runner control (IMRC) if required. Refer to INTAKE MANIFOLD
RUNNER CONTROL ACTUATOR .
5. Position the lower intake manifold.

1. Apply a bead of sealant to the lower intake manifold mounting at the points indicated.
2. Position the lower intake manifold.
Fig. 30: Identifying Position Lower Intake Manifold

Fig. 31: Installing Long Bolts

6. Install the six long bolts.

7. Install the eight short bolts.
Fig. 32: Installing Short Bolts

8. Make sure to tighten the bolts in two stages following the sequence shown.
l Stage 1: Tighten to 5 N.m (44 lb-in).
l Stage 2: Tighten to 10 N.m (89 lb-in).
Fig. 33: Bolt Tightening Sequence

9. Connect the water bypass tube.

1. Position the tube.
2. Install the bolts.
Fig. 34: Connecting Water Bypass Tube

10. Connect the intake manifold runner control (IMRC) electrical connector.
Fig. 35: Connecting Intake Manifold Runner Control (IMRC) Electrical Connector
11. Connect the upper radiator hose.

l Connect the hose.
l Position the clamp.
Fig. 36: Connecting Upper Radiator Hose

12. Connect the heater hose.
Fig. 37: Connecting Heater Hose

13. Connect the EGR to exhaust manifold tube.

l Tighten the nut.
Fig. 38: Connecting EGR To Exhaust Manifold Tube

14. Connect the EGR vacuum tube.
Fig. 39: Connecting 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 .
EXHAUST MANIFOLD
Removal (Left Side)
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. See Fig. 40. Remove exhaust manifold.
Installation (Left Side)
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. See Fig. 40. See TORQUE SPECIFICATIONS. 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 Side)
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. See Fig. 40. Remove exhaust manifold.
Installation (Right Side)
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. See Fig. 40. See TORQUE SPECIFICATIONS.
Fig. 40: Exhaust Manifold Bolt Tightening Sequence

CYLINDER HEAD
Removal
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.
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 reference. DO NOT reuse bolts. Remove cylinder head and gasket.
Inspection
1. Inspect cylinder head for cracks or warpage. Machine cylinder head if warpage exceeds specification. See
CYLINDER HEAD table under ENGINE SPECIFICATIONS.
2. Check cylinder block deck surface. Machine cylinder block if warpage exceeds specification. See
CYLINDER BLOCK table under ENGINE SPECIFICATIONS.
Installation
1. Ensure bolt holes in cylinder block are clean. Install gasket and cylinder head.
2. Install NEW cylinder head bolts. Tighten cylinder head bolts to specification in sequence. See Fig. 41.
See TORQUE SPECIFICATIONS.
Fig. 41: Cylinder Head Bolt Tightening Sequence

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 44 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. Final tightening of rocker arms may be done with camshaft in any
position.
5. To complete installation, reverse removal procedure. Tighten all bolts and nuts to specification. Refill
cooling system.
VALVE COVERS
Removal & Installation (Left Valve Cover)
1. Remove oil dipstick tube bracket bolt, and position oil dipstick tube and bracket aside. Remove spark
plug wire retainers, and position spark plug wires aside. Disconnect PVC valve. Remove valve cover
bolts, and remove valve cover.
2. To install, reverse removal procedure. Install new valve cover gasket if necessary. Tighten bolts to
specification. See TORQUE SPECIFICATIONS.
Removal & Installation (Right Valve Cover)
1. Remove cowl top vent panel. See COWL TOP VENT PANEL. Disconnect PVC tube. Disconnect brake
booster and fuel vapor return hoses. Remove Engine Vacuum Regulator (EVR) retaining nuts, and
position EVR aside. Remove ignition coil. Remove spark plug wire retainers, and position spark plug
wires aside.
2. To install, reverse removal procedure. Install new valve cover gasket if necessary. Tighten bolts to
specification. See TORQUE SPECIFICATIONS.
CRANKSHAFT FRONT OIL SEAL
Removal
Remove accessory drive belts. Place reference mark on crankshaft pulley and vibration damper. Remove splash
shield. Remove right front wheel. Remove vibration damper retaining bolt. Disconnect anti lock brake wheel
sensor electrical connector. Position safety stand under front subframe. Remove front subframe retaining bolts,
and lower subframe about 2 inches. Using Vibration Damper Remover (T58P-6316-D) and Adapter (T82L-
6316-B), remove vibration damper and pulley assembly. Using Oil Seal Remover (T92C-6700-CH), pry seal
from front cover.
Installation
1. Lubricate seal and sealing surfaces with engine oil. Using appropriate seal installer, 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. Ensure reference marks align on crankshaft pulley and vibration damper.
FRONT COVER
Removal
1. Disconnect negative battery cable. Drain cooling system. Remove cowl top vent panel. See COWL TOP
VENT PANEL. Disconnect coolant overflow bottle hose. Loosen drive belt tensioner and remove drive
belt. Remove generator adjustment and retaining bolts, and remove generator. Remove generator bracket
mount retaining bolts, and remove generator bracket assembly. Remove idler pulley. Disconnect oil
pressure sending unit, A/C compressor, and Intake Manifold Runner Control (IMRC) electrical
connectors.
2. Disconnect Crankshaft Position (CMP) sensor connector, and position wiring harness aside. Remove
power steering pump. Disconnect hoses from water pump. Note location of CMP sensor assembly
connector for installation reference, and disconnect connector. Rotate crankshaft to position piston No. 1
at TDC (compression stroke). Remove CMP sensor assembly, and note direction of camshaft position
sensor synchronizer assembly installation. Remove synchronizer housing retaining bolt. Remove
camshaft position sensor synchronizer housing along with intermediate shaft. Remove power steering
mounting bracket upper bolts.
3. Using Vibration Damper Remover (T58P-6316-D) and Adapter (T82L-6316-B), remove crankshaft
pulley and vibration damper. Remove Crankshaft Position (CKP) sensor. Disconnect Catalyst Monitor
(CMS) sensor. Remove (CMS) mounting bracket. Remove belt tensioner. Remove power steering pump
bracket lower bolts, and remove bracket. Disconnect radiator lower hose.
4. Raise vehicle. Drain engine oil and remove oil filter. Remove engine mount nuts. Lower vehicle. Install
Engine Lifting Bracket Set (D94L-6001-A) onto right and left side of engine. Attach engine crane to
engine lifting brackets, and raise engine about 5 inches. Remove water pump pulley. Remove 5 water
pump retaining nuts, and 4 water pump retaining bolts, and remove water pump, lower tube, and gasket as
an assembly. Remove water pump mounting studs.
5. Remove front cover bolts and nuts. One front cover bolt is hidden behind oil filter mounting flange.
Remove front cover and oil filter adapter as an assembly.
Installation
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 with NEW gasket.
Install studs into their original location. Tighten bolts and nuts in sequence (except bolt No. 12) to
specification. Tighten bolt No. 12, located behind oil filter mounting adapter, last. Tighten bolt No. 12 to
89 INCH lbs. (10 N.m). See Fig. 42. See TORQUE SPECIFICATIONS.
3. Install water pump pulley. Lower engine into position, and remove engine crane and lifting brackets.
Raise vehicle, and install engine mount nuts. To install remaining components, reverse removal
procedure. Coat seal surface of vibration damper with engine oil. Using appropriate vibration damper
installer, install vibration damper.
4. Install camshaft position sensor synchronizer assembly and camshaft position sensor. For camshaft
position sensor synchronizer removal, installation and alignment procedure, see:
2000 Windstar
REMOVAL, OVERHAUL & INSTALLATION article in ENGINE PERFORMANCE
2001 Windstar
REMOVAL, OVERHAUL & INSTALLATION - TRUCKS - GASOLINE article in ENGINE

PERFORMANCE
5. Ensure reference marks on crankshaft pulley and vibration damper align. To complete installation, reverse
removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Refill cooling
system and engine oil.
Fig. 42: Front Cover Bolt Tightening Sequence

TIMING CHAIN
Removal
1. Remove front cover. See FRONT COVER. Ensure timing marks on all gears align. See Fig. 44. Remove
retaining bolt, and remove camshaft position sensor synchronizer assembly drive gear.
2. Remove camshaft gear, crankshaft gear and timing chain. See Fig. 43. If crankshaft gear is difficult to
remove, position a pair of screwdrivers evenly on gear and carefully pry it off.
3. Remove tensioner assembly by pulling back on ratcheting mechanism and installing a pin through hole in
bracket. Remove retaining bolts, and remove tensioner assembly. See Fig. 43.
Fig. 43: Exploded View Of Timing Chain & Components

Installation
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 Fig. 44. With all timing marks aligned, remove pin from tensioner/snubber assembly to apply
tension to timing chain.
3. Install CMP synchronizer. See CMP SYNCHRONIZER.
4. Tighten bolts to specification. See TORQUE SPECIFICATIONS. To install remaining components,

reverse removal procedure.
Fig. 44: Aligning Timing Marks

VALVE LIFTER
Removal
1. Remove upper and lower intake manifolds. See INTAKE MANIFOLD. 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. Mark valve lifter location
for reassembly reference. Remove valve lifters.
Inspection
Inspect valve lifter for damage. Ensure roller rotates smoothly and has no flat spots or scoring. Measure valve
lifter O.D. and cylinder block lifter bore I.D. to determine oil clearance. If oil clearance is not as specified,
replace components. See VALVE LIFTERS table under ENGINE SPECIFICATIONS.
Installation
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. Install guide plate retainer. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
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 44 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.
CAMSHAFT
Removal
1. Remove engine. See ENGINE. Remove upper intake manifold, upper intake manifold spacer and lower
intake manifold. See INTAKE MANIFOLD. Remove valve lifters. See VALVE LIFTER.
2. Remove engine front cover and timing chain. See FRONT COVER and TIMING CHAIN . Remove oil
pan. See OIL PAN. Remove camshaft. DO NOT damage camshaft bearing surfaces.
Inspection
Inspect components for damage. Measure camshaft bearing I.D., journal O.D., and lobe lift. Replace
components if damaged or not within specification. See CAMSHAFT table under ENGINE
SPECIFICATIONS.
Installation
1. To install, reverse removal procedure. Ensure oil holes in camshaft bearings and cylinder block align.
Apply sealant onto rear camshaft bore plug before installing.
2. Lubricate camshaft lobes and bearing surfaces with Assembly Lubricant (D9AZ-19579-C). Install
camshaft. Tighten thrust plate bolts to specification. See TORQUE SPECIFICATIONS.
3. Ensure camshaft end play is within specification. See CAMSHAFT table under ENGINE
SPECIFICATIONS. To complete installation, reverse removal procedure. Refill cooling system.
CMP SYNCHRONIZER
For camshaft position sensor synchronizer removal, installation and alignment procedure, see:
2000 Windstar
REMOVAL, OVERHAUL & INSTALLATION article in ENGINE PERFORMANCE
2001 Windstar
REMOVAL, OVERHAUL & INSTALLATION - TRUCKS - GASOLINE article in ENGINE

PERFORMANCE
BALANCE SHAFT
Removal
1. Remove engine. See ENGINE. Remove timing chain and gears. See TIMING CHAIN.
2. Remove balance shaft drive gear from camshaft. Remove balance shaft thrust plate bolts. Remove
balance shaft. See Fig. 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.
Fig. 45: Locating Balance Shaft & Thrust Plate

Inspection
Inspect components for damage. Measure balance shaft journal O.D. and runout. Replace components if
damaged or not within specification. See BALANCE SHAFT SPECIFICATIONS table.
BALANCE SHAFT SPECIFICATIONS

End Play .003-.008 (.08-.20)
Journal O.D. 2.0505-2.0515 (52.083-52.108)
Runout .001 (.03)
Installation
1. To install, reverse removal procedure. Lubricate all components with engine oil before installation. Apply
sealant to rear bore plug before installing.
2. Ensure all timing marks align. See Fig. 44. Check balance shaft end play. Replace thrust plate if end play
is not within specification. See BALANCE SHAFT SPECIFICATIONS table.
CRANKSHAFT REAR OIL SEAL
Removal
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.
Installation
1. Lubricate seal and mating surfaces with engine oil. Install seal on crankshaft with spring side toward
crankshaft. Using Seal Service Set (T95T-6701-AR), 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.
RADIATOR
Removal & Installation
1. Disconnect the battery ground cable. Drain the cooling system. Disconnect the upper radiator hose from
the radiator. Disconnect the electrical connectors and the harness.
2. Remove the upper radiator sight shield. Disconnect the overflow hose from the radiator. A/C condenser
must be secured. Tie the A/C condenser to the upper radiator support. See Fig. 46.
3. Remove the radiator guide pins. See Fig. 47. Raise and support the vehicle. Remove the five screws to
access the A/C condenser bolts. See Fig. 48. Remove the bolt and position the A/C muffler bracket out of
the way.
4. Disconnect the lower radiator hose and the degas bottle supply hose from the radiator. Disconnect the
transmission cooler tubes from the transmission. See Fig. 49. Unclip the transmission cooler tubes from
the lower radiator support. See Fig. 50.
5. Disconnect the auxiliary cooler line from the retainer. Remove the auxiliary cooler retainer bolts and
remove the cooler. See Fig. 51. Remove the four bolts and the radiator support. See Fig. 52.
6. Remove the bolts from the A/C condenser. Remove the radiator, fan and the shroud assembly. Remove
the bolts, the fan, and the shroud assembly from the radiator. Using the special tool, disconnect the
transmission tubes from the radiator.
7. To install, reverse the removal procedure. Tighten bolts to specification. See TORQUE
SPECIFICATIONS.
Fig. 46: Securing A/C Condenser To Upper Radiator Support

Fig. 47: Locating Radiator Guide Pins

Fig. 48: Locating Screws To Access A/C Condenser

Fig. 49: Locating Transmission Cooler Tubes At Transmission

Fig. 50: Locating Clip On Transmission Cooler Tubes

Fig. 51: Locating Auxiliary Cooler Bolts

Fig. 52: Locating Radiator Support Bolts

THERMOSTAT
Removal & Installation
1. Drain the engine cooling system. Remove the air cleaner outlet tube. Remove the upper radiator hose
from the water hose connector.
2. Mark the location of the vent pin before removing the thermostat. Remove the bolt, nut, water hose
connector and thermostat, and discard the gasket.
3. To install, reverse removal procedure. Tighten to specification. See TORQUE SPECIFICATIONS.
WATER PUMP
Removal
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
generator. Disconnect power steering pump pressure hose. Remove cowl top vent panel. See COWL
TOP VENT PANEL.
2. Disconnect water by-pass hose. Remove water pump outlet tube retaining bolt, and position tube
assembly aside. Attach lifting equipment to left exhaust manifold. Raise engine approximately 5" (127
mm). Remove accessory belt pulley nut, and remove pulley. Remove generator support bracket.
3. Remove water pump pulley. Remove water pump bolts, nuts and studs, noting location of studs. Remove
water pump, lower tube and gasket as an assembly.
Installation
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. Install studs into
original location. Tighten bolts and nuts in sequence to specification. See Fig. 53. See TORQUE
SPECIFICATIONS. Fill cooling system.
Fig. 53: Water pump Bolt & Nut Tightening Sequence

OIL PAN
Removal
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 inspection cover. Remove oil pan-to-
transmission mounting bolts. Remove retaining bolts, oil pan and seals.
Installation
To install, reverse removal procedure. Before installing oil pan, apply Silicone Sealant (E3AZ-19652-A) onto
oil pan rails of cylinder block, rear main bearing cap and front cover-to-cylinder block areas. Tighten oil pan
bolts in sequence to specification. Fig. 54See TORQUE SPECIFICATIONS. Fill engine with oil.
Fig. 54: Oil Pan Bolt Tightening Sequence

CYLINDER HEAD
Cylinder Head
Check cylinder head warpage. Resurface cylinder head if warpage exceeds specification. See CYLINDER
HEAD table under ENGINE SPECIFICATIONS.
Valve Springs
1. Inspect pressure of valve spring. Replace valve spring if pressure is not within specification. See
VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.
2. 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 table.
3. 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 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
1. Valve guides may be reamed for oversize valves if stem-to-guide oil clearance exceeds specification. See
CYLINDER HEAD table under ENGINE SPECIFICATIONS. Valves are available in .015" (.38 mm)
and .030" (.76 mm) oversizes.
2. 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. Grind valve seats after 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.
Valve Seat Correction Angles
Use a 30-degree stone to lower seat, or a 60-degree stone to raise seat.
CYLINDER BLOCK ASSEMBLY
Piston & Rod Assembly
Install piston on connecting rod. Position piston dome or notch on same side as button on connecting rod. See
Fig. 55. Install piston and connecting rod into engine. Position piston with dome or notch on piston's top and
button on connecting rod toward front of engine.
Fig. 55: Positioning Piston & Connecting Rod

Fitting Pistons
1. 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 table under ENGINE SPECIFICATIONS.
2. 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 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
1. 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 Fig. 55.
2. Use Plastigage method to check bearing oil clearance. DO NOT rotate crankshaft while using plastigage.
See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS and CONNECTING RODS
tables under ENGINE SPECIFICATIONS.
3. If oil clearance exceeds specification, try using a different combination of rod bearings. See
SELECTIVE MAIN & ROD BEARINGS table. Use only bearing combinations listed in table.
4. 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.
5. 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.
Crankshaft & Main Bearings
1. Ensure main bearing oil clearance and crankshaft end play is within specification. See CRANKSHAFT,
MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS. Replace thrust
bearing if end play is not within specification.
2. If oil clearance exceeds specification, try using a different combination of main bearings. See
SELECTIVE MAIN & ROD BEARINGS table. Use only bearing combinations listed in table.
3. If any bearing cannot be adjusted to standard oil clearance specification, grind crankshaft and use
oversize bearings. Main bearings are available in .010" (.25 mm) oversize. Tighten main bearing cap bolts
to specification.
SELECTIVE MAIN & ROD BEARINGS

Use Lower
Amount Of Excess Use Upper Bearing Bearing - In.
Clearance - In. (mm) - In. (mm) (mm)
0.0-.0005 (0.0-.013) .001 (.025) (1)
.0005-.0010 (.013- .001 (.025) .001 (.025)

.026)
.0010-.0015 (.026- .002 (.050) .001 (.025)
.039)
.0015-.0020 (.039- .002 (.050) .002 (.050)
.052)
(1) Use standard bearing.
4. 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.
5. 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.
6. Tighten bolts finger tight. Pry crankshaft forward, and tighten main bearing cap bolts to specification. See
TORQUE SPECIFICATIONS. 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
1. Using a straightedge and feeler gauge, check cylinder block head surface warpage. Machine cylinder
block if warpage exceeds specification. See CYLINDER BLOCK table under ENGINE
SPECIFICATIONS.
2. 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 table under ENGINE
SPECIFICATIONS.
ENGINE LUBRICATION SYSTEM
Force-feed type system supplies pressurized oil to crankshaft, connecting rods, camshaft and balance shaft
bearings, and valve lifters. A controlled volume of oil is supplied to rocker arms and push rods. Oil pump is
driven by intermediate shaft connected to CMP synchronizer assembly.
Crankcase Capacity
Crankcase capacity, including filter, is 4.5 qts. (4.3L).
Oil Pressure
Oil pressure is 40-125 psi (2.8-8.8 kg/cm2 ) at 2500 RPM with engine at normal operating temperature.
OIL PUMP
Removal & Disassembly
Raise vehicle. Drain engine oil. Remove oil filter and oil cooler (if equipped). Remove oil filter housing bolts,
and remove oil pump drive gear, driven gear, "O" ring seal and oil pump cover. See Fig. 56. Note direction of
component installation.
Fig. 56: Exploded View Of Oil Pump Components

Inspection
1. Place straightedge across mounting surface of oil pump cover. Measure warpage between oil pump cover
and straightedge. Replace oil pump or cover if warpage exceeds specification. See OIL PUMP
SPECIFICATIONS table.
2. Measure gear thickness and gear pocket depth in pump body. Check gear side clearance by measuring
from tip of gear to pump housing. Measure gear diameter and gear pocket diameter in front cover.
Replace components if measurements are not within specification. See OIL PUMP SPECIFICATIONS
table.
3. Check relief valve tension and relief valve-to-bore clearance. Replace components if measurements are
not within specification. See OIL PUMP SPECIFICATIONS table.
OIL PUMP SPECIFICATIONS

Driver Shaft-To-Housing Clearance .0015-.0030 (.076-.038)
Idler Shaft-To-Gear Clearance .0004-.0017 (.010-.044)
Oil Pump Gear Backlash .008-.012 (.02-.03)
Oil Pump Gear Height (1) .0040-.0004 (.100-.010)
Oil Pump Gear Radial Clearance .002-.005 (.050-.125)
Relief Valve-To-Bore Clearance .0017-.0029 (.043-.073)
Lbs. @ In. (kg @ mm)
Relief Valve Spring Tension 15.2-17.1 @ 1.20 (6.9-7.8 @ 28.2)
(1) Measure amount gear is recessed in housing
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. To install, reverse
removal procedure. Tighten bolts to specification.
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Accessory Drive Belt Tensioner 18 (25)
Brake Caliper Bolts 26 (35)
Camshaft Sprocket Bolt 33 (45)
Connecting Rod Nut
Step 1 18 (25)
Step 2 33 (45)
Step 3 Additional 90-120 Degrees
Crankshaft Pulley 118 (160)
Cylinder Head Bolt (1)
Step 1 15 (20)
Step 2 30 (40)
Step 3 37 (50)
Step 4 (2) Back Off 2-3 Turns
Step 5
Long Bolt
1st Step 33 (45)
2nd Step Additional 175-185 Degrees
Short Bolt
1st Step 18 (25)
2nd Step Additional 175-185 Degrees
Engine Mount
Left Side Bolts 46 (63)
Left Side Mount-to-Subframe Nuts 76 (103)
Right Side Bolts 46 (63)
Right Side Mount-to-Subframe Nuts 66 (90)
Exhaust Manifold Bolt/Nut 18 (25)
Flywheel/Drive Plate Bolt (3) 59 (80)
Front Cover Bolts 1-11 & 13 (4)18 (25)
Front Subframe Bolts 66 (90)

Main Bearing Cap Bolt/Stud
Step 1 37 (50)
Step 2 Additional 115-125 Degrees
Oil Filter Adapter Bolt 18-22 (24-30)
Oil Pick-Up Tube Bolt/Nut
At Cylinder Block 18 (25)
At Main Bearing Cap 35 (48)
Oil Pan Baffle Bolt 35 (48)
Oil Pan-To-Transaxle Bolt 46 (62)
Oil Pump Bolt
Large Bolt 18 (25)
Small Bolt (5)
Power Steering Bracket Bolts

Large Bolt 35 (48)
Small Bolt 18 (25)
Rocker Arm Bolt (6)
Stabilizer Bar Nuts 70 (95)

Steering Shaft Pinch Bolt 30 (40)
Strut Mount Bolts 91 (124)
Subframe Bolt 66 (90)
Torque Converter Nut 27 (36)
Transaxle-To-Cylinder Block Bolt 37 (50)
Water Pump Bolt 18 (25)
INCH Lbs. (N.m)
Balance Shaft Thrust Plate Bolt 106 (12)
Camshaft Thrust Plate Bolt 106 (12)

Fuel Rail Bolts 89 (10)
Intake Manifold Spacer Bolts (7) 89 (10)
Inspection Cover Bolt 89 (10)
Lower Intake Manifold Bolts (7)
Step 1 45 (5)
Step 2 89 (10)
Oil Dipstick Retaining Bolt 89 (10)
Oil Pan Bolts 89 (10)
Power Steering Pressure Line Nuts 89 (10)
Thermostat Housing Bolt & Nut 108 (12)
Throttle Body Bolts 89 (10)
Timing Chain Vibration Damper Bolts 71-124 (8-14)
Upper Intake Manifold Bolts 89 (10)
Upper Intake Manifold Spacer Bolts 89 (10)
Upper Intake Manifold Stud Bolts 89 (10)
Valve Cover Bolts 89 (10)
Valve Tappet (Lifter) Guide Plate Bolts 108 (12)
Water By-Pass Tube Retaining Bolt 89 (10)
Water Pump Stud Bolt 62 (7)
(1) Use NEW cylinder head bolts. Apply sealant to shortest bolts. Tighten bolts in sequence. See Fig. 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 bolt No. 12 to 89 INCH lbs. (10 N.m).
(5) Tighten bolts to 89 INCH lbs. (10 N.m).
(6) Tighten bolt to 44 INCH lbs. (5 N.m) with valve lifter on base circle of camshaft. Once all rocker
arms are tightened, retighten bolts to 24 ft. lbs. (32 N.m).
(7) Tighten bolts in sequence.
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Specification
Displacement 232 Cu. In. (3.8L)
Bore 3.81" (96.8 mm)
Stroke 3.39" (86.1 mm)
Compression Ratio 9.0:1
Fuel System SFI
CRANKSHAFT, MAIN BEARINGS & CONNECTING ROD BEARINGS SPECIFICATIONS
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

Crankshaft End Play .004-.008 (.10-.20)
Main Bearings
Journal Diameter 2.5190-2.5198 (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 Diameter 2.3103-2.3111 (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)
CONNECTING RODS SPECIFICATIONS
CONNECTING RODS
Bore Diameter
Pin Bore .90315-.90472 (22.94-22.98)
Crankpin Bore 2.4266-2.4274 (61.636-
61.656)
Center-To-Center Length 6.089-6.092 (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)
PISTONS, PISTON PINS & PISTON RINGS SPECIFICATIONS
PISTONS, PINS & RINGS

Pistons
Piston Clearance .0007-.0017 (.018-.044)
Diameter (1)
Red 3.8103-3.8108 (96.782-96.795)
Blue 3.8108-3.8113 (96.795-96.808)
Yellow 3.8113-3.8118 (96.808-96.821)
Pins
Diameter .9055-.9056 (23.000-23.003)
Piston Fit .0004-.0007 (.011-.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).
CYLINDER BLOCK SPECIFICATIONS
CYLINDER BLOCK
Cylinder Bore
Standard Diameter 3.81 (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 & 4 2.191-2.192 (55.651-55.677)
No. 2 & 3 2.176-2.177 (55.270-55.296)
Main Bearing Bore 2.712-2.713 (68.88-68.91)
(1) DO NOT machine more than .010" (.25 mm) from original cylinder block deck surface.
ENGINE VALVES & VALVE SPRINGS SPECIFICATIONS
VALVES & VALVE SPRINGS

Intake Valves
Face Angle 45.675°
Head Diameter 1.86" (47.27 mm)
Minimum Margin .031" (.80 mm)
Stem Diameter .2738-.2751" (6.955-6.988 mm)
Valve Face Runout .002" (.05 mm)
Exhaust Valves
Face Angle 45.675°
Head Diameter 1.46" (37.1 mm)
Minimum Margin .031" (.80 mm)
Stem Diameter .2728-.2741" (6.929-6.962 mm)
Valve Face Runout .002" (.05 mm)
Valve Springs
Installed Height 1.62" (40.7 mm)
Lbs. @ In. (kg @ mm)
Pressure
Valve Closed 79 @ 1.62 (35.8 @ 40.7)
Valve Open 224 @ 1.16 (101 @ 29.2)
VALVE LIFTERS SPECIFICATIONS
VALVE LIFTERS
Lifter Diameter .8740-.8745 (22.200-22.212)
Oil Clearance
Standard .0007-.0027 (.018-.069)
CYLINDER HEAD SPECIFICATIONS
CYLINDER HEAD
Maximum Warpage (1) .007" (.18 mm)
Valve Seats
Intake Valve
Seat Angle 44.75°
Seat Width .06-.08" (1.5-2.0 mm)
Maximum Seat Runout .003" (.08 mm)
Exhaust Valve
Seat Angle 44.75°
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.
CAMSHAFT SPECIFICATIONS
CAMSHAFT
Camshaft Bearing I.D. 2.0525-2.0535 (52.134-52.159)
End Play .001-.006 (.0255-.152)
Journal Diameter 2.067-2.075 (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).

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2000-01 ENGINES 3.

ENGINE IDENTIFICATION CODES

VALVE CLEARANCE ADJUSTMENT

COLLAPSED VALVE LIFTER CLEARANCE

martes, 9 de junio de 2020 07:42:17

Application In. (mm)

VALVE CLEARANCE CHECKING SEQUENCE

FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS

Fig. 1: Disconnecting Fuel Lines

COWL TOP VENT PANEL

2. To install, reverse removal procedure.

Intake Manifold - Upper

Removal and Installation

l Remove the two bolts and the IAC valve.

Fig. 2: Removing Bolts And IAC Valve

Courtesy of FORD MOTOR CO.

Fig. 3: Removing Fuel Line Retaining Clip

Fig. 4: Removing Alternator Wire Harness Retaining Clips

6. Position the spark plug wires aside.

l Position the spark plug wires aside.

Fig. 5: Identifying Position Spark Plug Wires Aside

7. Remove the upper intake manifold.

Fig. 6: Removing Upper Intake Manifold

Fig. 7: Disconnecting Accelerator And Speed Control Cables

9. Position the bracket aside.

l Remove the stud bolt.

l Position the bracket aside.

Fig. 8: Identifying Bracket Bolts

10. Disconnect the throttle position (TP) sensor electrical connector.

Fig. 9: Disconnecting Throttle Position (TP) Sensor Electrical Connector

11. Disconnect the evaporative emissions return tube.

Fig. 10: Disconnecting Evaporative Emissions Return Tube

12. Disconnect the brake booster vacuum hose.

Fig. 11: Disconnecting Brake Booster Vacuum Hose

14. Disconnect the vacuum hose.

Fig. 13: Disconnecting Vacuum Hose

15. Disconnect the fuel pressure regulator vacuum tube.

Fig. 14: Disconnecting Fuel Pressure Regulator Vacuum Tube

16. Disconnect the positive crankcase ventilation (PCV) hose.

Fig. 15: Disconnecting Positive Crankcase Ventilation (PCV) Hose

17. Remove the upper intake manifold spacer.

l Remove the intake manifold spacer.

Fig. 16: Removing Upper Intake Manifold Spacer

18. To install, reverse the removal procedure.

Fig. 17: Tightening Upper Intake Manifold Spacer

Fig. 18: Tightening Upper Intake Manifold

Intake Manifold - Lower

MATERIAL SPECIFICATION CHART

Fig. 19: Disconnecting EGR Vacuum Tube

5. Disconnect the EGR-to-exhaust manifold tube.

Fig. 20: Disconnecting EGR-To-Exhaust Manifold Tube

6. Disconnect the heater hose.

l Disconnect the hose.

Fig. 21: Disconnecting Heater Hose

7. Disconnect the upper radiator hose.

l Disconnect the hose.

Fig. 22: Disconnecting Upper Radiator Hose

8. Disconnect the intake manifold runner control (IMRC).

Fig. 23: Disconnecting Intake Manifold Runner Control (IMRC)

9. Position the water bypass tube aside.

Fig. 24: Positioning Water Bypass Tube Aside

10. Remove the lower intake manifold.

Fig. 25: Removing Lower Intake Manifold

Fig. 26: Removing Lower Intake Manifold Sealing Components