Ford Windstar 1995 - User Manual

REMOVAL AND INSTALLATION
Engine Front Cover
If the engine front cover (6019) is being removed to check timing chain deflection, refer to Timing Chain Deflection Procedure as outlined in Section 03-00.
Removal
1. Remove engine (6007) from vehicle. Refer to procedure in this section.
2. Loosen drive belt tensioner (6B209) and drive belt (8620) .
3. Remove water pump pulley retaining bolts and water pump pulley (8509) .
4. Remove retaining bolts and disconnect heater water outlet tube (18663) from water pump (8501) .
5. Disconnect electrical connector at camshaft position sensor.
6. Disconnect electrical connector at crankshaft position sensor (CKP sensor) (6C315) .
7. Remove retaining bolt and disconnect radiator lower hose tube (8291) from water pump .
NOTE: If the vibration damper and crankshaft pulley have to be separated, mark the vibration damper and crankshaft pulley so that they may be reassembled in the
same relative position. This is important as the vibration damper and crankshaft pulley are initially balanced as a unit.
NOTE: If the vibration damper is being replaced, check if the original vibration damper has balance pins installed. If so, new balance pins (6A328 or equivalent) must be
installed on the new vibration damper in the same position as the original vibration damper. The crankshaft pulley (new or original) must also be installed in the same
relative position as originally installed.
8. Remove crankshaft pulley (6312) and vibration damper assembly using Crankshaft Damper Remover T58P-6316-D and Vibration Damper Remover Adapter T82L-6316-B.
9. Remove four retaining bolts and remove brace from A/C bracket and P/S bracket.
10. Remove oil bypass filter (6714) .
CAUTION: The engine front cover cannot be removed without lowering the oil pan (6675) .
11. Remove oil pan . Refer to procedure in this section.
CAUTION: Do not overlook the engine front cover retaining bolt located behind the oil pump and filter body (6603) . The engine front cover will break if pried upon
and all retaining bolts are not removed.
12. Remove engine front cover retaining bolts. It is not necessary to remove water pump .
13. Remove engine front cover and water pump as an assembly.
14. Remove engine front cover gasket and discard.
Water Pump Tightening Sequence
Section 03-01: Engine, 3.8L 1995 Windstar Workshop Manual
SPECIAL SERVICE TOOL(S) REQUIRED
Description Tool Number
Crankshaft Damper Remover T58P-6316-D
Vibration Damper and Seal Replacer T82L-6316-A
Vibration Damper Remover Adapter T82L-6316-B
3
1995 Windstar
6/3/2009
http://www.fordtechservice.dealerconnection.com/pubs/content/~WSSW/~MUS~LEN/20/S
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Summary

Engine Front Cover Removal

Crankshaft Damper and Pulley Removal

Procedure for removing the crankshaft pulley and vibration damper assembly using specialized tools.

Oil Pan Removal Prerequisite

The engine front cover cannot be removed without first lowering the oil pan.

Engine Front Cover and Water Pump Removal

Steps to remove the engine front cover and water pump as a single assembly.

Engine Front Cover Installation

Gasket Surface Preparation

Cleaning gasket surfaces on the engine front cover and cylinder block before installation.

Water Pump Installation

Installing the water pump onto the engine front cover with retaining bolts.

Crankshaft Front Seal Lubrication

Lubricating the crankshaft front seal with specified engine oil before installation.

Engine Front Cover Gasket and Installation

Positioning the front cover gasket and installing the engine front cover assembly.

Crankshaft Pulley Installation

Installing the crankshaft pulley using the vibration damper and seal replacer tool.

Overview

1. Function Description
2. Usage Features (Removal and Installation Process)
3. Removal
4. Installation
5. Maintenance Features

This document outlines the detailed procedures for the removal and installation of the engine front cover on a 1995 Ford Windstar, specifically for the 3.8L engine. The primary function of the engine front cover is to enclose and protect critical internal engine components, such as the timing chain and gears, while also providing mounting points for various accessories like the water pump and crankshaft position sensor. It plays a crucial role in maintaining the integrity of the engine's timing system and preventing oil leaks.

Function Description:

The engine front cover serves as a protective barrier for the timing chain, which synchronizes the rotation of the crankshaft and camshaft, ensuring proper valve timing. It also houses the crankshaft front seal, which prevents oil leakage from the front of the crankshaft. Additionally, the front cover provides a mounting surface for the water pump, an essential component of the engine's cooling system, and the oil pump and filter body, which are integral to the lubrication system. The camshaft and crankshaft position sensors, vital for engine management, are also typically mounted on or near the front cover, allowing them to monitor the rotational positions of these components. The design of the cover ensures that these components are shielded from external contaminants and damage, contributing to the overall longevity and reliable operation of the engine. Its removal is often necessary for maintenance or repair tasks involving the timing chain, crankshaft front seal, water pump, or oil pump.

Usage Features (Removal and Installation Process):

The removal and installation process for the engine front cover is comprehensive and requires careful attention to detail, as outlined in the manual.

Removal:

1. Engine Removal: The first step involves removing the entire engine from the vehicle. This is a significant undertaking, indicating that front cover service is not a minor repair and often necessitates extensive access to the engine.
2. Accessory Disconnection: Before the cover itself can be accessed, several peripheral components must be disconnected or removed. This includes loosening the drive belt tensioner and removing the drive belt, which powers various engine accessories.
3. Water Pump and Heater Tube: The water pump pulley and its retaining bolts are removed, followed by the disconnection of the heater water outlet tube from the water pump. This highlights the integrated nature of the cooling system with the front cover.
4. Sensor Disconnection: Electrical connectors for the camshaft position sensor and crankshaft position sensor (CKP sensor) must be disconnected. These sensors are critical for engine timing and fuel injection control.
5. Radiator Hose: The radiator lower hose tube is disconnected from the water pump, further isolating the cooling system.
6. Crankshaft Pulley and Vibration Damper: A critical step involves removing the crankshaft pulley and vibration damper assembly. The manual emphasizes the importance of marking these components for reassembly in their original relative positions, as they are balanced as a unit. If the vibration damper is being replaced, specific instructions are provided regarding the transfer or installation of balance pins to maintain proper engine balance. Special service tools, such as the Crankshaft Damper Remover and Vibration Damper Remover Adapter, are required for this step, underscoring the specialized nature of the task.
7. Brace Removal: Four retaining bolts and a brace connecting the A/C bracket and P/S bracket are removed.
8. Oil Bypass Filter: The oil bypass filter is removed, which is part of the lubrication system integrated with the front cover.
9. Oil Pan Lowering: A crucial caution is provided: the engine front cover cannot be removed without lowering the oil pan. This indicates a design where the front cover extends into or is sealed by the oil pan, requiring the pan to be moved to facilitate removal. The oil pan itself must be removed as a separate procedure.
10. Front Cover Bolt Removal: All retaining bolts for the engine front cover are then removed. A specific caution warns against overlooking a bolt located behind the oil pump and filter body, as attempting to pry the cover off with this bolt still in place will cause damage. The water pump does not need to be removed from the front cover at this stage, as they are removed as an assembly.
11. Gasket Removal: Finally, the engine front cover and water pump are removed as an assembly, and the old front cover gasket is discarded.

Installation:

1. Surface Preparation: The installation process begins with cleaning the gasket surfaces on both the engine front cover and the cylinder block to ensure a proper seal. If the existing front cover is being reused, the crankshaft front seal must be replaced.
2. New Front Cover Preparation (if applicable): If a new engine front cover is being installed, the oil pump and filter body must be installed onto it. The water pump gasket surface is cleaned, a new water pump housing gasket is positioned, and the water pump is installed with its retaining bolts tightened to a specified torque.
3. Crankshaft Front Seal Lubrication: The crankshaft front seal is lubricated with clean engine oil to aid installation and prevent damage.
4. Gasket Positioning: The manual recommends using a gasket and trim adhesive to hold the new engine front cover gasket in position on the cylinder block, which helps during the assembly process.
5. Front Cover Assembly: The engine front cover / water pump assembly is then positioned onto the cylinder block, using dowels for proper alignment.
6. Bolt Installation and Torque: The engine front cover retaining bolts are installed and tightened to a specified torque range. A specific capscrew, nearest the oil bypass filter flange, is noted to be installed and tightened last, with Loctite® or equivalent applied to it.
7. Oil Pan and Filter: The oil pan is installed as outlined in its separate procedure, followed by the installation of the oil bypass filter.
8. Pulley Sealing Surface: The pulley sealing surface is coated with clean engine oil.
9. Silicone Sealer Application: If silicone rubber sealer is used, the assembly must occur within 15 minutes of application to ensure effective sealing. A small amount of silicone gasket and sealant is applied to the crankshaft keyway.
10. Crankshaft Key: The crankshaft key is positioned in the crankshaft keyway.
11. Crankshaft Pulley Installation: The crankshaft pulley is installed using the Vibration Damper and Seal Replacer tool.
12. Pulley Retaining Bolt: The crankshaft pulley retaining washer and bolt are installed and tightened to a high torque specification.
13. Pulley to Damper: If the pulley was separated from the vibration damper, it is reinstalled, and its retaining bolts are tightened to a specified torque.
14. Brace Reinstallation: The brace connecting the A/C bracket and P/S bracket is reinstalled, with its M8 and M10 retaining bolts tightened to their respective torque specifications.
15. Hose and Sensor Connections: The radiator lower hose tube, crankshaft position sensor electrical connector, and camshaft position sensor electrical connector are reconnected.
16. Heater Water Outlet Tube: The heater water outlet tube is reconnected to the water pump, and its retaining bolts are tightened.
17. Water Pump Pulley: The water pump pulley and its retaining bolts are installed and tightened to a specified torque.
18. Drive Belt: The drive belt is positioned over the pulleys and the drive belt tensioner, referring to a separate section for this procedure.
19. Engine Installation: Finally, the engine is installed back into the vehicle, referring to a separate procedure for this extensive task.

Maintenance Features:

The document itself is a maintenance guide, providing step-by-step instructions for a significant engine service operation. Key maintenance features embedded within the instructions include:

• Special Service Tools: The requirement for specific tools like the Crankshaft Damper Remover and Vibration Damper and Seal Replacer highlights the need for specialized equipment to perform this maintenance correctly and safely, preventing damage to components.
• Torque Specifications: Precise torque specifications are provided for numerous bolts (e.g., water pump retaining bolts, engine front cover retaining bolts, crankshaft pulley bolt, brace retaining bolts, water pump pulley bolts). Adhering to these specifications is crucial for ensuring proper sealing, preventing leaks, and securing components, which directly impacts engine reliability and longevity.
• Gasket and Seal Replacement: The instructions explicitly state to replace the engine front cover gasket and, if reusing the front cover, the crankshaft front seal. This emphasizes preventive replacement of wear items to avoid future leaks and maintain engine integrity.
• Lubrication and Sealants: The use of clean engine oil for the crankshaft front seal and pulley sealing surface, along with silicone gasket and sealant for the crankshaft keyway, are critical for proper function and leak prevention. The time-sensitive nature of silicone sealer application (within 15 minutes) is a vital detail for effective sealing.
• Component Marking and Balancing: The instruction to mark the vibration damper and crankshaft pulley for reassembly in their original relative positions, and the guidance on balance pins for new vibration dampers, underscores the importance of maintaining engine balance to prevent vibrations and premature wear.
• Pre-installation Cleaning: The emphasis on cleaning gasket surfaces before installation is fundamental to achieving a reliable, leak-free seal.
• Cautionary Notes: Numerous "CAUTION" notes are interspersed throughout the document, warning technicians about potential damage (e.g., breaking the front cover if a bolt is overlooked, the need to lower the oil pan). These warnings are crucial for preventing costly mistakes and ensuring a successful repair.
• Cross-referencing: The document frequently cross-references other sections of the workshop manual (e.g., for timing chain deflection, engine removal, oil pan removal, drive belt positioning, engine installation). This indicates a comprehensive and integrated maintenance system, where different procedures are linked to provide a complete picture for the technician.

In essence, this manual provides a detailed, systematic approach to a complex engine repair, ensuring that technicians follow best practices for component handling, assembly, and sealing, all of which are critical for the long-term performance and reliability of the 1995 Ford Windstar's 3.8L engine.

Ford Windstar 1995 Specifications

General

Engine Type	V6
Horsepower	155 hp
Transmission	4-speed automatic
Fuel Type	Gasoline
Drivetrain	Front-wheel drive
Seating Capacity	7
Wheelbase	120.7 inches
Engine Option	3.0L V6
Torque (3.0L)	170 lb-ft
Fuel Tank Capacity	20 gallons