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DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSFORD1999WINDSTAR BASE, VAN CARGO, 3.8 4REPAIR AND DIAGNOSIS (SINGLE PAGE)EXTERNAL PAGESDIFFERENT CARSECTION 1791 (ENGINE MECHANICAL - 3.0L (4V))SPECIFICATIONSGENERAL SPECIFICATIONS TABLE
1999 Ford Windstar Base, Van Cargo, 3.8 4
General Specifications Table
1999 Ford Windstar Base, Van Cargo, 3.8 4SECTION General Specifications Table
WARNING: This page is about a different car, the 2010 Mercury Milan and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
GENERAL SPECIFICATIONS TABLE
| Item | Specification | ||
|---|---|---|---|
| Engine | |||
| Bore/stroke | 89.0 x 79.5 mm (3.12 in) | ||
| Compression ratio | 10.3:1 | ||
| Displacement | 3.0L (4V) (182 Cubic Inch Displacement (CID)) | ||
| Engine and transaxle assembly weight (without accessory drive components) | 234 kg (516 lb) | ||
| Engine weight (without accessory drive components and flexplate) | 146 kg (322 lb) | ||
| Fire order | 1-4-2-5-3-6 | ||
| No. cylinders | 6 | ||
| Oil pressure (Minimum at 1,500 rpm with engine warmed up after 10 minutes of idling) | 172 kPa (25 psi) | ||
| Spark plug | CGSF-22F Gap = 1.15-1.25 mm (0.045-0.049 in) |
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| Cylinder Head and Valve Train | |||
| Combustion chamber volume | 51.2 cc +/- 1.5 cc | ||
| Cylinder head gasket surface flatness | 0.025 mm (0.001 in) in any 25 mm (1 in) X 25 mm (1 in) area, 0.05 mm (0.002 in) in any 150 mm (6 in) area, 0.15 mm (0.005 in) overall | ||
| Roller follower ratio @ max. lift | 2.0:1 | ||
| Valve arrangement (front to rear) | LH intake I-I-I-I-I-I LH exhaust E-E-E-E-E-E RH intake I-I-I-I-I-I RH exhaust E-E-E-E-E-E |
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| Valve face angle | 45.5 degrees | ||
| Valve face runout | 0.04 mm (0.001 in) | ||
| Valve guide bore diameter | 6.015-6.044 mm (0.236-0.237 in) | ||
| Valve head diameter - exhaust | 30 mm (1.18 in) | ||
| Valve head diameter - intake | 35 mm (1.38 in) | ||
| Valve head diameter (exhaust) - gauge diameter | 28.0 mm (1.10236 in) | ||
| Valve head diameter (intake) - gauge diameter | 33.5 mm (1.3189 in) | ||
| Valve seat angle | 44.75 degrees | ||
| Valve seat runout | 0.04 mm (0.001 in) | ||
| Valve seat width - exhaust | 1.4-1.7 mm (0.055-0.066 in) |
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| Valve seat width - intake | 1.1-1.4 mm (0.043-0.055 in) |
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| Valve spring compression pressure (Nm @ spec. length) | 780 Nm @ 32.29 mm (575 lb @ 1.27 in) |
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| Valve spring free length (approx.) | 50.52 mm (1.988 in) | ||
| Valve spring installed height (Nm @ spec. length) | 42.61 mm (1.677 in) | ||
| Valve spring installed pressure | 280 Nm @ 42.61 mm (206 lb @ 1.677 in) | ||
| Valve spring installed pressure - service limit | 5% force loss @ specified height | ||
| Valve spring squareness | 1.2 mm (0.047 in) from ID | ||
| Valve stem diameter - exhaust | 5.950-5.970 mm (0.2343-0.2350 in) | ||
| Valve stem diameter - intake | 5.975-5.995 mm (0.2350-0.2358 in) | ||
| Valve stem-to-guide clearance - exhaust | 0.045-0.094 mm (0.0017-0.037 in) | ||
| Valve stem-to-guide clearance - intake | 0.019-0.069 mm (0.0007-0.0027 in) | ||
| Hydraulic Lash Adjuster | |||
| Clearance to bore | 0.018-0.069 mm (0.0007-0.0027 in) | ||
| Collapsed lash adjuster gap | 0.50-1.11 mm (0.019-0.043 in) | ||
| Diameter (standard) | 16-15.988 mm (0.6290-0.6294 in) | ||
| Hydraulic leakdown rate | 5-25 seconds | ||
| Camshaft | |||
| Camshaft journal bore inside diameter | 27.012-26.987 mm (1.063-1.062 in) | ||
| Camshaft journal-to-bearing clearance - service limit | 0.121 mm (0.0047 in) | ||
| Camshaft journal-to-bearing clearance - standard | 0.025-0.076 mm (0.001-0.0029 in) | ||
| End play - service limit | 0.241 mm (0.009 in) | ||
| Journal diameter (all) | 26.962-26.936 mm (1.061-1.060 in) | ||
| Lobe lift (intake) | 5.084 mm (0.2 in) | ||
| Lobe lift (exhaust) | 5.084 mm (0.2 in) | ||
| Runout | - | ||
| Theoretical valve lift @ 0 lash | 10.38 mm (0.408 in) | ||
| Cylinder Block | |||
| Cylinder bore diameter - grade 1 | 89.000-89.010 mm (3.50393-3.504323 in) | ||
| Cylinder bore diameter - grade 2 | 89.011-89.020 mm (3.50437-3.50472 in) | ||
| Cylinder bore diameter - grade 3 | 89.021-82.030 mm (3.50476-3.50511 in) | ||
| Cylinder bore maximum out-of-round | 0.015 mm (0.0005 in) | ||
| Cylinder bore maximum out-of-round - service limit | 0.020 mm (0.0007 in) | ||
| Cylinder bore maximum taper | 0.020 mm (0.0008 in) | ||
| Head gasket surface flatness | 0.025 mm (0.001 in) in any 25 mm (1 in) X 25 mm (1 in) area, 0.05 mm (0.002 in) in any 150 mm (6 in) area, 0.15 mm (0.005 in) overall | ||
| Main bearing bore inside diameter | 67.998-68.022 mm (2.677-2.6780 in) | ||
| Crankshaft | |||
| Connecting rod journal diameter | 49.969-49.991 mm (1.967-1.968 in) | ||
| Connecting rod journal maximum out-of-round | 0.006 mm (0.0002 in) | ||
| Connecting rod journal maximum taper | 0.008 mm (0.0003 in) | ||
| Crankshaft maximum end play | 0.100-0.255 mm (0.003-0.100 in) | ||
| Main bearing journal diameter | 62.968-62.992 mm (2.467-2.479 in) | ||
| Main bearing journal maximum out-of-round | 0.006 mm (0.0002 in) | ||
| Main bearing journal maximum taper | 0.008 mm (0.0003 in) | ||
| Main bearing journal-to-cylinder block clearance | 0.024-0.046 mm (0.0009-0.0018 in) (select fit bearings) | ||
| Piston and Connecting Rod | |||
| Connecting rod bearing bore diameter | 53.015-53.035 mm (2.0872-2.0879 in) | ||
| Connecting rod bearing-to-crankshaft clearance | 0.028-0.066 mm (0.001-0.0025 in) | ||
| Connecting rod length (center-to-center) | 138.06-138.14 mm (5.435-5.38 in) | ||
| Connecting rod maximum allowed bend | 0.038 mm per 25 (0.0014 per 0.984 in) |
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| Connecting rod maximum allowed twist | 0.050 mm per 25 (0.0019 per 0.984 in) |
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| Connecting rod pin bore diameter | 21.017-21.031 mm (0.827-0.828 in) | ||
| Connecting rod side clearance | 0.100-0.30 mm (0.0039-0.0118 in) | ||
| Connecting rod-to-pin clearance - service limit | 0.035 mm (0.0013 in) | ||
| Connecting rod-to-pin clearance - standard | 0.004-0.02 mm (0.0001-0.0007 in) | ||
| Piston diameter - coated, grade 1 | 88.980-88.995 mm (3.5031-3.5037 in) | ||
| Piston diameter - coated, grade 2 | 88.78-89.007 mm (3.4952-3.5042 in) | ||
| Piston diameter - coated, grade 3 | 89.00-89.015 mm (3.5039-3.5045 in) | ||
| Piston diameter - uncoated, grade 1 | 88.970-88.980 mm (3.50275-3.50314 in) | ||
| Piston diameter - uncoated, grade 2 | 88.978-88.992 mm (3.50306-3.50362 in) | ||
| Piston diameter - uncoated, grade 3 | 88.990-89.000 mm (3.5035-3.5039 in) | ||
| Piston pin bore diameter | 21.015-21.020 mm (0.8273-0.8275 in) | ||
| Piston pin diameter | 21.011-21.013 mm (0.8271-0.8273 in) | ||
| Piston pin length | 60.08-60.51 mm (2.365-2.382 in) | ||
| Piston ring end gap - compression (bottom, gauge diameter) | 0.27-0.42 mm (0.0106-0.0165 in) | ||
| Piston ring end gap - compression (bottom, service limit) | 0.65 mm (0.0255 in) max | ||
| Piston ring end gap - compression (top, gauge diameter)(1) | 0.100-0.250 mm (0.0039-0.0098 in) | ||
| Piston ring end gap - compression (top, service limit) | 0.50 mm (0.0196 in) max | ||
| Piston ring end gap - oil ring (steel rail, gauge diameter) | 0.15-0.65 mm (0.0059-0.0255 in) | ||
| Piston ring end gap - oil ring (steel rail, service limit) | 0.90 mm (0.0354 in) max | ||
| Piston ring groove width - compression (bottom) | 1.530-1.555 mm (0.0602-0.0612 in) | ||
| Piston ring groove width - compression (top) | 1.230-1.255 mm (0.0484-0.0494 in) | ||
| Piston ring groove width - oil ring | 2.53-2.555 mm (0.0996-0.1005 in) | ||
| Piston ring-to-groove clearance | - | ||
| Piston ring width | - | ||
| Piston pin-to-piston fit | 0.002 to 0.009 mm (0.00007-0.0003 in) | ||
| Piston-to-connecting rod clearance | - | ||
| Piston-to-cylinder bore clearance (coated) | 0.003 to 0.032 mm (0.0001-0.0012 in) | ||
| Piston-to-cylinder bore clearance (uncoated) | 0.012 to 0.022 mm (0.0005-0.0009 in) | ||
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RENDER: 1.0x
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.