Tools You'll Need:
* Repair Manual: Essential for torque specs and specific procedures.
* Socket Set: Various sizes, including metric and potentially SAE.
* Wrench Set: Combination wrenches are helpful.
* Ratchet and Extensions: To reach tight spots.
* Torque Wrench: Absolutely crucial to avoid over-tightening bolts.
* Valve Cover Gasket Set: Buy a kit that includes the gaskets, new seals, and potentially grommets.
* New Spark Plugs (Recommended): While you're in there, it's a good idea to replace them.
* Clean rags or shop towels: Plenty of them.
* Pliers: For removing stubborn connectors.
* A small pry bar or flathead screwdriver (plastic is preferred): For carefully prying up the old gasket.
* Engine degreaser (optional): For cleaning the engine before and after.
* Gloves: To protect your hands.
* Jack and Jack Stands (or ramps): For safe access to the engine.
Steps:
1. Safety First: Disconnect the negative battery terminal. Support the vehicle securely with jack stands.
2. Preparation: Clean the engine bay around the valve covers. This will make the job cleaner and easier.
3. Remove Components:
* Disconnect spark plug wires: Carefully remove and label them to ensure correct reinstallation.
* Disconnect PCV hose(s): Locate and disconnect any PCV hoses connected to the valve covers.
* Disconnect any other components: This might include sensors or wiring harnesses connected to the valve covers. Again, carefully label everything.
4. Remove the Valve Covers:
* Locate and remove the valve cover bolts: These are usually 10mm or 8mm bolts. Loosen them evenly before removing them completely to prevent warping the valve cover.
* Carefully lift off the valve cover: There might be some resistance from the old gasket. Use a plastic pry tool to gently separate the valve cover from the cylinder head.
5. Clean the Valve Covers and Cylinder Head: Thoroughly clean the valve covers and the mating surfaces on the cylinder head. Remove all traces of the old gasket material. Use a gasket scraper if needed, but be careful not to scratch the surfaces.
6. Install the New Gaskets: Carefully install the new valve cover gaskets, ensuring they are properly seated in their grooves.
7. Reinstall the Valve Covers: Carefully position the valve covers and install the bolts, tightening them evenly in a crisscross pattern. Use your torque wrench to tighten the bolts to the manufacturer's specifications. This is crucial to prevent leaks and damage.
8. Reconnect Components: Reconnect the spark plug wires, PCV hoses, and any other components you disconnected, ensuring everything is properly seated.
9. Lower Vehicle: Carefully lower the vehicle from the jack stands.
10. Check for Leaks: After reconnecting the battery, start the engine and check for any leaks around the valve covers. Let it run for a few minutes.
11. Re-torque if Necessary: If you find a leak, let the engine cool down, re-tighten the bolts (to spec), and check again.
Important Considerations:
* Torque Specifications: This is the most critical part. Using the wrong torque can strip the bolt threads or warp the valve cover.
* Gasket Material: Ensure you're using the correct gasket material for your engine.
* Year-Specific Differences: The exact procedure may vary slightly depending on the year and engine of your Windstar. Consult your repair manual.
* Difficulty: This is not a beginner-level repair. If you're not comfortable with basic engine work, it's best to take it to a mechanic.
This guide provides a general overview. Always refer to a factory service manual specific to your Windstar's year and engine for detailed instructions, torque specifications, and diagrams. Improperly performing this repair can lead to engine damage. If in doubt, consult a qualified mechanic.
