How to Repair a Head Gasket on a Windstar
The head gasket lies between the engine block and cylinder head, and keeps the motor oil and coolant from mixing as they flow through the engine block. The head gasket also seals the internal combustion in the pistons, helping them maintain pressure and function. You may need to repair your head gasket when the engine overheats or under other circumstances such as dirty bolts, improper gasket design or installation problems.
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Instructions
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1
Make sure the Ford Windstar has a cold engine before you start working under the vehicle's hood. Disconnect the cable from the negative battery. Drain the coolant system by unscrewing the plug located in the rear of the power steering pump or below the air condition compressor. This prevents coolant from spilling into the pistons and crankcase.
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2
Ticket and label the Ford Windstar before you remove and disconnect the car parts. Detach or remove the air intake duct, ignition wires, air cleanser outlet tubes, fuel system pressure and vacuum lines assembly. Disconnect each hose: the upper radiator hose, coolant bypass hose and heater hose. Disconnect the belt from the power steering pump and remove the tank from the mount. Place the components on a workbench. Do not disconnect the hydraulic line.
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3
Place wooden blocks on top of padded floor jacks underneath the Windstar. Remove the brackets from the engine anchor on the left side in the front. Slip the compressor belt from around the engine and get rid of the alternator belt tension bracket. Take off the distributor anchor and disconnect the fuel line. Plug up the fuel line to prevent the fluid from spilling.
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4
Remove the distributor housing and detach the fuel line that connects the intake manifold fuel rail. Seal the fuel line to stop fuel from leaking. Undo the throttle cable nut and slip it off.
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5
Separate the top engine components and the connectors: manifold absolute pressure sensor connection, engine coolant temperature sensor electrical connector, crankshaft position sensor electrical connector, exhaust gas recirculation valve electrical connector and camshaft position electrical connector. Remember the location of every component as you label each part.
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6
Disconnect the upper engine parts and all the connectors from the camshaft position electrical connector, crankshaft position sensor electrical connector, engine coolant temperature sensor electrical connector, manifold absolute pressure sensor connection and exhaust gas recirculation valve electrical connector. Note the position of each part even as you ticket and label.
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7
Undo the cylinder head bolts in a crisscross sequence in the reverse installation order. Undo the bolt the farthest away and move toward the middle of the cylinder head. Remove the cylinder head and check for damage. Replace the cylinder head if required. Clean the cylinder head if you do not replace. Lubricate new bolts and bolt threads before installing. Clean the head gasket mating surface.
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8
Position the new head gasket and find the "up" mark to guide you. Align with the dowels in the engine block.
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Place the cylinder head on top of the cylinder block. Place the cylinder head bolts in a two-step process. Torque to 37 foot-pounds for the first step. Torque to 68 foot-pounds for the second step.
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Replace each engine block component in the reverse order of the original set-up. Consult a Ford Windstar service manual for the appropriate bolt torque.
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Tips & Warnings
Use a service manual to help identify the parts of the Windstar.
