Safety Warning
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 1793 (ENGINE MECHANICAL - 2.5L (HYBRID))DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIESPISTONASSEMBLY
1999 Ford Windstar Base, Van Cargo, 3.8 4
Disassembly And Assembly Of Subassemblies: Piston: Assembly
1999 Ford Windstar Base, Van Cargo, 3.8 4SECTION Assembly
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.
- Align the piston-to-connecting rod orientation marks, and position the connecting rod in the piston.NOTE: The arrow on the top of the piston points towards the front of the engine.
- Lubricate the piston pin and pin bore with clean engine oil.
- Install the piston pin in the piston and connecting rod assembly.
- Install the piston pin retaining clips in the piston.
- Lubricate the piston and the new piston rings with clean engine oil.
- Install the piston rings onto the piston as shown.
- Piston pin
- Upper oil control ring gap location
- Lower oil control ring gap location
- Center line of the piston pin bore and the expander gap
NOTE: The piston compression upper and lower ring should be installed with the paint mark on the outside diameter circumference of the ring to be positioned on the right side of the ring gap. The lower compression ring can also be installed with the undercut side downward.
RENDER: 1.0x
NO RELATED
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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.