Engine Manual

Engine Manual
Make: Ford Truck
Model: Winstar
Year: 2002
Engine Displacement: 3.8L
Transmission Type: Automatic

1.
Remove left and right valve
covers. Valve covers protect
the valve train and keep oil
and fluids in so they stay
lubricated
On Assembly:
Torque bolts and stud bolts

to 89 Lb-In. Check gaskets
and replace if necessary.
2.
Remove the lower intake
manifold. The intake
manifold distributes the
combustion mix into the
cylinder heads
On Assembly:
Position the gaskets.

Position the intake manifold.
Torque in two stages in the
pattern shown on next page
1. 44 Lb-In
2. 89 Lb-In
3.
Remove Front Engine Cover.
The front engine cover
protects the timing chain
assembly and keeps it
lubricated
On Assembly:
Torque stud No. 4,5, 6,7,10

to 62 In-Lbs.
Torque bolt No. 12 to 89

In-Lbs.
Torque all other bolts to 21

lb-ft. In the sequence shown
on next slide.
4.
Remove rocker arms.
Rocker arms open and
close the valves
On Assembly:
Torque rocker arms in two

stages:
1. 44 inch lbs.
2. 24 ft. lbs
5.
Remove push rods. Push
rods push the rocker
arms which open and
close the valves
On Assembly:
Lubricate push rods with

clean engine oil before
installation.
6.
Remove cylinder heads.
Cylinder heads are the top of
the combustion chamber.
The air and fuel mixture
enters the combustion
chamber through the cylinder
heads.
On Assembly:
Check head gaskets
Torque long bolts to 33 lb-ft
plus 175-185 degrees
Torque short bolts to 18 lb-ft
plus 175-185 degrees in
sequence shown. ( short
bolts 2,4,6,8. Long bolts
1,3,5,7)
7.
Remove oil pan. The oil
pan collects all of the oil
that runs down to the
bottom of the engine.
On Assembly:
Torque to 89 lb-in in
pattern shown on right.
8.
Remove crankshaft
damper and pulley
system. The pulley
system connects to the
other engine components
with a belt.
On Assembly:
Torque to 118 lb-ft.

9.
Remove the tensioner and
timing chain assembly. The
timing chain connects the
camshaft to the crankshaft
and makes sure the valves
open and close at the right
time. The tensioner keeps
the timing chain tight.
On Assembly:
Assemble as a unit and line

your timing marks up.
10.
Remove valve
tappets/lifters. The lifters
ride on the camshaft and
lift the push rods which
push on the end of the
rocker arms and opens
the valves
On Assembly:
Lubricate valve tappets

with clean engine oil and
torque to 9 lb-ft.
11.
Remove balance shaft Balance Shaft
drive gear and thrust
plate and remove balance
shaft. The balance shaft
offsets vibrations.
On Assembly:
Line timing marks on

drive gear up with
camshaft drive gear.
Torque thrust plate to 9
lb-ft.
12.
Remove camshaft drive
gear, thrust plate, and pull
camshaft straight out.
The camshaft is
connected to the
crankshaft and is timed to
help open the valves at
the right time.
On Assembly:
Torque thrust plate to 9

lb-ft. Line up timing
marks.
13.
Remove oil pump screen,
tube and baffle. The oil
pump pumps oil from the
bottom of the engine (in
the oil pan) back up to the
top so it can recirculate
back to the bottom and
cool the engine.
On Assembly: Baffle
Torque baffle to 24 lb-ft
Oil pump screen
Torque oil pump tube to and tube
18 lb-ft
14.
Remove the connecting rod caps
and remove the pistons out the
bottom of the cylinders. (*Be
careful not to damage cylinder
walls*). Pistons are connected to
the crankshaft and convert force
from the combustion of fuel and
air to turn the crankshaft.
On Assembly: Compress
piston rings and carefully tap
pistons back in bottom of the
cylinder. Torque connecting rod
caps in three stages:
1. 18 ft. lbs
2. 33 ft. lbs
3. 90-120 degrees
15.
Remove crankshaft
bearing caps. The
bearing caps keep the
crankshaft in the right
spot and help to lubricate
it.
On Assembly:
Torque to 37 ft. lbs plus

115-125 degrees
16.
Remove crankshaft. The
crankshaft is connected
to the pistons and
converts the piston
movement into a circular
rotating movement.
On Assembly:
Lubricate bearing journals

with new engine oil and
inspect for damage.
17. Tools Used
Clean engine block ● Breaking bar
with pressure washer and ● Socket set
all other parts with varsol. ● Torque Bar
Reassemble. ● Piston ring compressor
● Harmonic Balancer puller
● Plastigage
● Pressure washer
● Varsol tub

Engine Manual

Uploaded by

Copyright:

Available Formats

Engine Manual

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Engine Manual

Uploaded by

Copyright:

Available Formats

Engine Manual

Make: Ford Truck

Engine Displacement: 3.8L

Transmission Type: Automatic

Torque bolts and stud bolts

Position the gaskets.

Torque stud No. 4,5, 6,7,10

Torque bolt No. 12 to 89

Torque all other bolts to 21

Torque rocker arms in two

Lubricate push rods with

Torque to 118 lb-ft.

Assemble as a unit and line

Lubricate valve tappets

Line timing marks on

Torque thrust plate to 9

Torque to 37 ft. lbs plus

Lubricate bearing journals

You might also like