PRODEMAND Windstar cylinder User Manual
- June 5, 2024
- PRODEMAND
Table of Contents
1/7/22, 8:34 AM Printer Friendly View
YMMS: 2000 Ford Windstar Limited Jan 7, 2022
Engine: 3.8L Eng License:
VIN: Odometer:
CYLINDER HEAD [ REMOVAL & INSTALLATION ]
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.
CAUTION: DO NOT machine more than .010″ (.25 mm) from original cylinder head thickness or cylinder block surface.
2. Check cylinder block deck surface. Machine cylinder block if warpage exceeds specification. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS.
Installation
Question: Head Gasket position
CAUTION: Always use NEW cylinder head bolts. Coat all cylinder head bolts with engine oil before installing.
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 1. See TORQUE SPECIFICATIONS.
Fig 1: Cylinder Head Bolt Tightening Sequence
G95F12646
Courtesy of FORD MOTOR CO.
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.
NOTE: If cylinder head or valve train components are serviced, check valve clearance adjustment. See VALVE CLEARANCE ADJUSTMENTS under ADJUSTMENTS.
5. To complete installation, reverse removal procedure. Tighten all bolts and nuts to specification. Refill cooling system.
CYLINDER HEAD [ OVERHAUL ]
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.
Cylinder Head
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
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.
CAUTION: DO NOT install valve spring shims unless necessary. Using more shims than required can result in spring breakage or worn camshaft lobes.
NOTE: Lubricate all valves, valve stems and valve guides with heavy oil during installation. Use Multipurpose Grease (D0AZ-19584-AA) on valve tips.
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.
CAUTION: DO NOT ream valve guides from standard to maximum oversize in one step. Ream valve guides to oversize in gradual steps so valve guides are reamed true in relation to valve seat. Grind valve seats after valve guide is reamed or replaced.
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.
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.