Before you begin:
* Consult a repair manual: A Haynes or Chilton manual for your specific year and engine (likely a 3.0L Vulcan or a 3.8L Essex) is crucial. It will provide detailed instructions, torque specifications, and diagrams.
* Gather tools: You'll need a variety of tools, including sockets, wrenches (metric), a torque wrench (essential!), screwdrivers, possibly a timing chain tool to keep the chain from moving, a gasket scraper, and a clean work area.
* Safety first: Disconnect the negative battery terminal before starting any work on the engine.
General Steps (These are highly simplified):
1. Drain the coolant: The timing chain cover is usually located near the engine's front, and you'll likely need to drain some coolant to access it.
2. Remove accessory belts: You may need to remove the serpentine belt and possibly other accessories (power steering pump, alternator, etc.) to gain access.
3. Remove the timing chain cover: This will involve removing various bolts and possibly other components depending on the specific engine. Pay close attention to the order of removal and bolt locations. You might need to carefully remove some components to access the bolts.
4. Clean the surfaces: Thoroughly clean the mating surfaces of the engine block and the timing chain cover with a gasket scraper and a suitable cleaner. Any remaining gasket material needs to be removed.
5. Install the new gasket: Carefully install the new gasket, ensuring it's properly seated and aligned.
6. Reinstall the timing chain cover: Tighten the bolts in the proper sequence and torque specifications (found in your repair manual). Improper torque can lead to leaks or damage.
7. Reinstall components: Reinstall any accessories, belts, etc., that you removed earlier.
8. Refill coolant: Refill the cooling system with the correct type and amount of coolant.
9. Check for leaks: Start the engine and check for any leaks around the timing chain cover.
Important Considerations:
* Timing Chain Tensioner: Depending on the condition of your timing chain tensioner, you may want to consider replacing it as well. A worn tensioner can cause timing chain issues.
* Timing Chain: While not directly related to the gasket, if you have excessive slack or noise in your timing chain, consider replacing it as a preventative measure. This is a much more involved job.
* Engine Timing: If you remove the timing chain (rarely necessary for just a gasket replacement), you'll need to properly align the timing marks. Getting this wrong can cause serious engine damage.
Recommendation: This is a complex repair. If you're not comfortable working on engines or lack the necessary experience, it's strongly recommended that you take your Windstar to a qualified mechanic. The cost of a professional repair is often less than the cost of fixing potential damage caused by an improper repair.
