engine FORD WINDSTAR 1999 2.G Repair Manual

Driving style Ð good driving and fuel economy habits
Give consideration to the lists that follow and you may be able to change
a number of variables and improve your fuel economy.
Habits
²Smooth, moderate operation can yield up to 10% savings in fuel.
²Steady speeds without stopping will usually give the best fuel
economy.
²Idling for long periods of time (greater than one minute) may waste
fuel.
²Anticipate stopping; slowing down may eliminate the need to stop.
²Sudden or hard accelerations may reduce fuel economy.
²Slow down gradually.
²Drive at reasonable speeds (traveling at 105 km /h [65 mph] uses 15%
more fuel than traveling at 88 km/h [55 mph]).
²Revving the engine before turning it off may reduce fuel economy.
²Use of the air conditioner or defroster may reduce fuel economy.
²Use of speed control (if equipped) may improve fuel economy. Speed
control can help maintain a constant speed and reduce speed changes.
You may want to turn off the speed control in hilly terrain as
unnecessary shifting between third and fourth gears may occur and
could result in reduced fuel economy.
²Warming up a vehicle on cold mornings is not required and may
reduce fuel economy.
²Resting your foot on the brake pedal while driving may reduce fuel
economy.
²Combine errands and minimize stop-and-go driving.
Maintenance and care
220

Maintenance
²Keep tires properly inflated and use only recommended size.
²Operating a vehicle with the wheels out of alignment will reduce fuel
economy.
²Use recommended engine oil. Refer toLubricant Specifications.
²Perform all regularly scheduled maintenance items. Follow the
recommended maintenance schedule and owner maintenance checks
found in your vehicle Scheduled Maintenance Guide.
Conditions
²Heavily loading a vehicle or towing a trailer may reduce fuel economy
at any speed.
²Carrying unnecessary weight may reduce fuel economy (approximately
2 km/h [1 mpg] is lost for every 180 kg [400 lb] of weight carried).
²Adding certain accessories to your vehicle (for example bug
deflectors, rollover/light bars, running boards, ski/luggage racks) may
reduce fuel economy.
²Use of fuel blended with alcohol may lower fuel economy.
²Fuel economy may decrease with lower temperatures during the first
12±16 km (8±10 miles) of driving.
²Flat terrain driving improves fuel economy over hilly roads.
²Transmissions give their best fuel economy when operated in the top
cruise gear and with steady pressure on the gas pedal.
²Close windows for high speed driving.
EPA window sticker
Every new vehicle should have the EPA window sticker. Contact your
dealer if the window sticker is not supplied with your vehicle. The EPA
window sticker should be your guide for the fuel economy comparisons
with other vehicles.
It is important to note the box in the lower left corner of the window
sticker. These numbers represent the Range of Km/L (MPG) expected on
the vehicle, depending upon the driver's method of operation and
conditions.
Maintenance and care
221

EMISSION CONTROL SYSTEM
Your vehicle is equipped with various emission control components and a
catalytic converter which will enable your vehicle to comply with
applicable exhaust emission standards. To make sure that the catalytic
converter and other emission control components continue to work
properly:
²Use only unleaded fuel.
²Avoid running out of fuel.
²Do not turn off the ignition while your vehicle is moving, especially at
high speeds.
²Have the items listed in your Scheduled Maintenance Guide performed
according to the specified schedule.
The scheduled maintenance items listed in the Scheduled Maintenance
Guide are essential to the life and performance of your vehicle and to its
emissions system.
If other than Ford, Motorcraft or Ford-authorized parts are used for
maintenance replacements or for service of components affecting
emission control, such non-Ford parts should be equivalent to genuine
Ford Motor Company parts in performance and durability.
Do not park, idle, or drive your vehicle in dry grass or other dry
ground cover. The emission system heats up the engine
compartment and exhaust system, which can start a fire.
Illumination of the charging system warning light,Check Engine
indicator light or the temperature warning light, fluid leaks, strange
odors, smoke or loss of oil pressure, could indicate that the emission
control system is not working properly.
Exhaust leaks may result in entry of harmful and potentially
lethal fumes into the passenger compartment.
Maintenance and care
222

Do not make any unauthorized changes to your vehicle or engine. By
law, vehicle owners and anyone who manufactures, repairs, items, sells,
leases, trades vehicles, or supervises a fleet of vehicles are not permitted
to intentionally remove an emission control device or prevent it from
working. Information about your vehicle's emission system is on the
Vehicle Emission Control Information Decal located on or near the
engine. This decal identifies engine displacement and gives some tune up
specifications.
Please consult your ªWarranty Guideº for complete emission warranty
information.
Readiness for inspection/maintenance (I/M) testing
In some localities, it may be a legal requirement to pass an I/M test of
the on-board diagnostic (OBD-II) system. If your ªCheck Engine/Service
Engine Soonº light is on, refer to the description in theWarning Lights
and Chimessection of theInstrumentationchapter. Your vehicle may
not pass the I/M test with the ªCheck Engine/Service Engine Soonº light
on.
If the vehicle's powertrain system or its battery has just been serviced,
the OBD-II system is reset to a ªnot ready for I/M testº condition. To
ready the OBD-II system for I/M testing, a minimum of 30 minutes of city
and highway driving is necessary as described below:
²First, at least 10 minutes of driving on an expressway or highway.
²Next, at least 20 minutes driving in stop-and-go, city-type traffic with
at least four idle periods.
Allow the vehicle to sit for at least eight hours without starting the
engine. Then, start the engine and complete the above driving cycle. The
engine must warm up to its normal operating temperature. Once started,
do not turn off the engine until the above driving cycle is complete.
Maintenance and care
223

Cleaning the wheels
Wash with the same detergent as the body of your vehicle. Do not use
acid-based or alcohol-based wheel cleaners, steel wool, fuel or strong
detergents. Never use abrasives that will damage the finish of special
wheel surfaces. Use a tar remover to remove grease and tar.
Cleaning the engine
Engines are more efficient when they are clean because grease and dirt
buildup keep the engine warmer than normal. When washing:
²Take care when using a power washer to clean the engine. The high
pressure fluid could penetrate the sealed parts and cause damage.
²Do not spray with cold water to avoid cracking the engine block or
other engine components.
²Cover the highlighted areas to prevent water damage when cleaning
the engine.
²Never wash or rinse the engine while it is running; water in the
running engine may cause internal damage.
Cleaning plastic exterior parts
Use vinyl cleaner for routine cleaning. Clean with a tar remover if
necessary. Do not clean plastic parts with thinners, solvents or
petroleum-based cleaners.
Maintenance and care
232

MOTORCRAFT PART NUMBERS
Component 3.0L Vulcan V6 engine 3.8L OHV V6 engine
Air filter FA-1616 FA-1616
Fuel filter FG-986B FG-986B
Battery (standard) BXT-59 BXT-65-650
Battery (optional) BXT-65±650 BXT-65-750
Oil filter FL-400S FL-400S
PCV valve EV-155 EV-152
Spark plugs* AWSF-32PP** AWSF-42EE***
* Refer to Vehicle Emissions Control Information (VECI) decal for spark
plug gap information.
** If a spark plug is removed for inspection, it must be reinstalled in the
same cylinder. Cylinders No. 1, 2 and 3 have a ªPGº suffix. Cylinders No.
4, 5 and 6 have a ªPº suffix. If a spark plug needs to be replaced, use
only spark plugs with the service part number suffix letter ªPPº as shown
on the engine decal.
*** If a spark plug is removed for inspection, it must be reinstalled in the
same cylinder. Cylinders No. 1, 2, and 3 have a ªEGº suffix. Cylinders No.
4, 5, and 6 have a ªEº suffix. If a spark plug needs to be replaced, use
only spark plugs with the service part number suffix letter ªEEº as
shown on the engine decal.
Capacities and specifications
236

REFILL CAPACITIES
Fluid Ford Part
NameApplication Capacity
Brake fluid
1All Fill to MAX line
on reservoir
Engine oil
(includes filter
change)Motorcraft 5W30
Super Premium
Motor Oil3.0L engine 4.3L
(4.5 quarts)
3.8L engine 4.7L
(5.0 quarts)
Engine coolant
2Without rear
heater14.0L
(14.8 quarts)
With rear heater 15.0L
(15.9 quarts)
Fuel tank N/A All 98.4L
(26.0 gallons)
Automatic
transaxle fluidMotorcraft
MERCONtV
AT FAll 11.6L
(12.25 quarts)
Windshield
washer fluidUltra-Clear
Windshield
Washer
ConcentrateAll Fill to line on
reservoir
1Use only brake fluids certified to meet Ford specifications. Refer to
Lubricant Specificationsin this chapter. DOT 3 fluid is recommended.
However, if DOT 3 is not available, DOT 4 fluid can be used.
2If your engine coolant is green in color, use Ford Premium Cooling
System Fluid. If your coolant is orange in color, use Ford Extended Life
Engine Coolant. Refer toAdding engine coolant, in the Maintenance
and Care chapter.
Capacities and specifications
237

LUBRICANT SPECIFICATIONS
Item Ford part
nameFord part
numberFord
specification
Brake fluid High
Performance
DOT 3 Motor
Vehicle Brake
Fluid
1
C6AZ-19542-AB ESA-M6C25-A
and DOT 3
Door
weatherstripsSilicone
LubricantF7AZ-
19G208-BA and
F5AZ-19553-AAESR-M13P4-A
Engine coolant Ford Premium
Engine Coolant
(green in color)E2FZ-19549-AA ESE-M97B44-A
Ford Extended
Life Engine
Coolant (orange
in color)F6AZ-19544-AA WSS-M97B44-D
or DEX-COOLt
equivalent
Engine oil Motorcraft 5W30
Super Premium
Motor OilXO-5W30-QSP WSS-M2C153-G
with API
Certification
Mark
Door latch, hood
latch,auxiliary
hood latch, door
and liftgate
hinges, striker
plates, seat
tracks and fuel
filler door hinge.Multi-Purpose
GreaseD0AZ-19584-AA
or F5AZ-
19G209-AAESB-M1C93-B or
ESR-M1C159-A
Lock cylinders Penetrating
LubricantE8AZ-19501-B none
Power steering
fluidMotorcraft
MERCONtAT FXT-2-QDX MERCONt
Automatic
transaxle
(AX4S)Motorcraft
MERCONtV
AT FXT-5-QM MERCONtV
Capacities and specifications
238

Item Ford part
nameFord part
numberFord
specification
Disc brake
caliper railsSilicone Brake
Caliper and
Dielectric
compoundD7AZ-19A331-A
(Motorcraft
WA-10)ESE-M1C171-A
Constant
velocity jointsCV Joint Grease
(High Temp.)E43Z-19590-A ESP-M1C207-A
Windshield
washer fluidUltra-Clear
Windshield
Washer
ConcentrateC9AZ-19550-AC ESR-M17P5-A
1Use only brake fluids certified to meet Ford specifications. DOT 3 fluid
is recommended. However, if DOT 3 is not available, DOT 4 fluid can be
used.
ENGINE DATA
Engine 3.0L V6 Vulcan
engine3.8L OHV V6 engine
Cubic inches 182 232
Horsepower 150 @ 5000 rpm 200 @ 4900 rpm
Torque 186 lb.-ft. @ 3750 rpm 240 lb.-ft. @ 3600 rpm
Recommended fuel 87 octane 87 octane
Firing order 1-4-2-5-3-6 1-4-2-5-3-6
Spark plug gap 1.07-1.17 mm
(0.042-0.046 inch)1.07-1.17 mm
(0.042-0.046 inch)
Ignition system EDIS EDIS
Compression ratio 9.3:1 9.3:1
VEHICLE DIMENSIONS
Vehicle dimensions Wagon mm (in) Van mm (in)
(1) Overall length 5 102.9 (200.9) 5 102.9 (200.9)
(2) Overall width 1 945.6 (76.6) 1 945.6 (76.6)
Capacities and specifications
239

IDENTIFYING YOUR VEHICLE
Safety compliance label
The National Highway Traffic Safety
Administration Regulations require
that a Safety Compliance
Certification Label be affixed to a
vehicle and prescribe where the
Safety Compliance Certification
Label may be located. The Safety
Compliance Certification Label is
located on the front door latch pillar
on the driver's side.
Vehicle identification number
The vehicle identification number is
attached to a metal tag and is
located on the driver side
instrument panel.
Engine number
The engine number (the last eight numbers of the vehicle identification
number) is stamped on the engine block, transmission, frame and
transfer case (if equipped).
MFD. BY FORD MOTOR CO. IN U.S.A.
EXT PNT: XXXXXX XXXXXX RC: XX DSO: XXXX F0000
BAR INT TR TP/PS R AXLE TR SPR T0000
X XX XXX X XX X XXXX
UTC
ÑFOHT-15294A10-GA
MAXIMUM LOAD=OCCUPANTS + LUGGAGE=XXXKG/XXXXLB
OCCUPANTS: X TOTAL X FR X 2ND X RR OCCUPANTS LUGGAGE
XX XXXKG/XXXXLB
TIRE: XXXX/XXXXX XXX X XXXKG/XXXXLB
PRESSURE (FR) XXX kPa/33 PSI COLD
PRESSURE (RR) XXX kPa/33 PSI COLD
TRAILER TOWING - SEE OWNER GUIDE
DATE: XXXXX GVWR:XXXXX LB/ XXXXX KG
VIN: XXXXXXXXXXXXXXXXX TYPE: XXXXXXXXXXXXXXX FGAWR: XXXXXX/XXXXXXX RGAWR: XXXXXXX/XXXXXXX
THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL
MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE
DATE OF MANUFACTURE SHOWN ABOVE.
XXXXXXXXXXXXXXXXX
AIR BAG
Capacities and specifications
241