engine transplant

I have a 95 3.8 Windstar that I am transplanting a 2000 3.8 Windstar motor into. Can anyone advise on potential mating problems, particularily re: MIRC intake control? Can I stay w/95 intake? Thanks.

I would not expect the intake manifolds to match up between the 2 motors.
This job would be well beyond me.....matching up the electrical.......add to that.....they made a lot of changes in the 1999 model year......and the intake is even further changed from the 1996-1998.....which I would not expect to match up either.
Unless you REALLY know what you are doing.....you could be creating a lot of issues with this project.

Thanx for your thoughts. I sorta thought the same but I've got the motor & the van & access to a defunct 2000 Winny sooooo.... I gotta try. I'll let you know how it goes.:evillol:

I have wiring diagrams for the PCM / engine sensors & controls for both model years, also the power distribution diagrams for both, all in pdf format, so I've sent you some links.

If you are in a area that either does not have vehicle emissions testing.....or an area that does not test older than 1996, then you might be able to get away with it.
I was originally thinking of emisssions testing........like we have where I am....but last year, they dropped testing 1995 and older.

Thanx for the diagrams, very helpful. I don't have emissions testing out here in the woods. After previewing it looks like I'll be using the 2000's PCM & plug n playing most everything else.

I was thinking about the '95 wiring harness and whether or not it would be compatible with the 2000 engine. I think you'll run into problems there, for example:

The '95 uses an ignition control module (ICM), which the 2000 doesn't. If you look at the foot of the 1995 PCM diagram, page 1, you'll see the ignition coil with its three sets of windings (only three because the plugs are fired in pairs) - follow the yellow/black, yellow/red and yellow/white wires up the page and you can see that the ICM is controlling the windings.

Now compare that with the ignition coil arrangement on the 2000 (PCM diagram, page 1 again) - follow the dark blue/light green, red/light blue, pink/white wires and you'll see that the coil windings are being driven directly by the PCM - there is no ICM.

Another example of a difference in components and hence probably a difference in the wiring harness is the MAF sensor - it's at the foot of PCM diagram, page 4 - the '95 has a four-pin sensor, while the 2000 has a six-pin.

There will probably be other differences but they're a couple of obvious ones. I can't see that the 2000 engine is going to plug straight into a '95 harness, so you'll need to give that some thought.

I'm not sure if this is an issue or not but I'll mention it anyway just in case it is - the '95 controls its lighting circuits via something called the Generic Electronic Module (GEM), while the 2000 uses both a Front Electronic Module (FEM) and a Rear Electronic Module (REM). I don't know if those modules communicate with the PCM, but if they do then there might be a problem when the 2000 PCM, fitted into the '95, tries to communicate with an FEM and REM, but finds just a single GEM instead. I believe the modules communicate using the Standard Corporate Protocol (SCP), so if you want to do some digging and find out if the modules do communicate with the PCM, then reading up on Ford's implementation of the SCP would be a good place to start.

The electrical work involved in the swap could be a real headache, as Wiswind already said, and that's not counting any mechanical incompatibilities which you might uncover.

Let me say that you peoples are very nice to help even though you're making me :banghead:.
To go back to the beginning, I have a comfy 95 Winny that I've used in my paint contracting business for 10+ yrs. Among other mods it has a trans rebuilt to bullet proof status. After the flawed headgasket failure happened I installed improved gaskets & new everything else coolant system which, after working well for 37k miles, sizzled to a halt on the fleeway (headgasket again). I thought I could install this 50k improved '00yr 3.8 to make all well but now that you guys have slapped me down with your reality rant I don't know....:confused:.

Regarding the '95 headgasket problem, is it a flawed head casting or engine design issue (could I use the '00 block/'95 heads to resolve)?

Am I over thinking this & would be best served by regasketing the existing motor even though I would probably like the added hp alot?

I am going to finish removing all accessories, etc today so I'm ready to drop out whilst I rethink my path:grinyes::grinno:.

From my understanding.....the head for any year after 1995 will not match.....even from a 1996.
It is my understanding that in 1996, they thickened the casting slightly at the thin spot(s) that were causing the issue.

I am wondering if the '95 computer and wire harness would be best for the newer motor.
Wire the IMRC in the CLOSED position.....as open will give you problems at the low RPM......and give you poor fuel economy.

Take note......you will be on new ground.......I am not a mechanic by any means........so I cannot say if it will or will not work......or what problems you might come up with.
For instance, from reading through the multiple page post that Searcherr was going through.......he found that the 1995 used a different fuel injector than even the 1996....so that is a potential problem point........would the fuel injectors from the '95 install in the newer motor without issue?.....I don't know.......would the newer motor work just fine with its own fuel injectors?....again....I don't know.
Will the motor mounts line up?.....again....I don't know.
This is why I am not going to talk out my rear end and speculate about the swap working.......as changing a motor....even with the same year.......is a lot of work......and I don't want to guide you down a path based upon speculation.......and have it not work.

I certainly hear you on liking the vehicle......my '96 at over 220K miles.....original motor......tranny replaced with a FORD remanufactured at about 100K miles (yearly tranny fluid exchange with Redline D4 and a auxillary cooler for the new unit)......when people saw my Sienna.......I got a lot of requests to buy my Windstar from me.

For all the trash talking folks do about the Windstar......mine gave me EXCEPTIONAL service......and I certainly got a LOT of use for the money out of it.
Original head gaskets.....original water pump......motor needed new lower intake manifold gaskets.....very common issue on MANY vehicles......new ones are improved....so it should be a 1 time only repair.
I bought my '96 used in '99.......for about 14K.....had just under 38K miles on it.
Had my youth group on a mission trip a month later.....pulling a trailer.
11 years later.....10 mission trips......over 220K miles.......and STILL in excellent mechanical condition.....(yes....many normal wear items replaced over the years...as can be seen in my pictures......normal part of owning a vehicle for a long time).

One thing the windstar has over my 2003 sienna.....the Sienna is terrible for seeing to back up.......just finished installing a backup camera onto it.
Although, otherwise...I am very happy with my Sienna......but it is a LOT newer than the windstar.......so newer technology......although it is slightly smaller than the windstar (they made them bigger starting in 2004).
I would still be driving my Windstar, except for family worrying about me driving around in such a old vehicle with so many miles on it......and I haul my youth group in it.....so you can picture what I would be hearing, should anything go wrong with the vehicle on a trip .

I have wiring diagrams for the PCM / engine sensors & controls for both model years, also the power distribution diagrams for both, all in pdf format, so I've sent you some links.

Hi there! If possible, I need to have you resend the links you refer to above. Thanx lots, KidAirless.

Yep, no problem.

1995 PCM & engine sensors/controls, diagram 1 (http://selectron.webs.com/1995-windstar-pcm-01.pdf), 2 (http://selectron.webs.com/1995-windstar-pcm-02.pdf), 3 (http://selectron.webs.com/1995-windstar-pcm-03.pdf), 4 (http://selectron.webs.com/1995-windstar-pcm-04.pdf)
2000 PCM & engine sensors/controls, diagram 1 (http://selectron.webs.com/2000-windstar-pcm-01.pdf), 2 (http://selectron.webs.com/2000-windstar-pcm-02.pdf), 3 (http://selectron.webs.com/2000-windstar-pcm-03.pdf), 4 (http://selectron.webs.com/2000-windstar-pcm-04.pdf)


1995 Power distribution, diagram 1 (http://selectron.webs.com/1995-windstar-power-distribution-01.pdf), 2 (http://selectron.webs.com/1995-windstar-power-distribution-02.pdf), 3 (http://selectron.webs.com/1995-windstar-power-distribution-03.pdf), 4 (http://selectron.webs.com/1995-windstar-power-distribution-04.pdf)
2000 Power distribution, diagram 1 (http://selectron.webs.com/2000-windstar-power-distribution-01.pdf), 2 (http://selectron.webs.com/2000-windstar-power-distribution-02.pdf), 3 (http://selectron.webs.com/2000-windstar-power-distribution-03.pdf), 4 (http://selectron.webs.com/2000-windstar-power-distribution-04.pdf)