Difference in 2000 vs. 2001 Windstar
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Difference in 2000 vs. 2001 Windstar
I have both a 2000 Ford Windstar SEL and a 2001 Windstar SEL. They each have the 3.8l engine. They each had a rod to break. I pulled the engine out of the 2000, One piston had the connecting rod shattered in pieces in the oil pan. Another connecting rod was bent. I measured (with a micrometer) the bearing journals on the crankshaft, and they were all within spec. I measured the bores of each cylinder, and they were each within spec.
I decided to try to rebuild this motor. I pulled the motor out of the 2001, and used two of the good pistons on the engine I was rebuilding. I used plastigage on each bearing journal and they were all within the specs I found in the Haynes manual. After I got it all back together, the fuel pump on the 2000 didn't work. I decided to take the fuel pump out of the 2001, and found out that they use different fuel pumps. On the 2000 fuel pump, the fuel pressure switch is on top of the the pump. The 2001 has the fuel pressure switch on the tank.
The 2001 pump worked in the 2000 Windstar, but I had a "Fuel Data Error". I assumed this was because the Fuel pressure switch was not plugged in. So, we changed out the fuel tank, using the 2001 tank, fuel lines, electrical connection, and I still get the "Fuel Data Error". I guess the computer is looking for the fuel pressure switch from the fuel pump, and instead it is on the tank.
It was surprising how many things had been changed on the Windstar from 2000 to 2001. Even the coil is in another place on the 2000 that it is on the 2001. The oil pan on the 2000 is steel, and the oil pan on the 2001 is cast aluminum.
It's educational working on two "identical but a year apart" Windstars.
I decided to try to rebuild this motor. I pulled the motor out of the 2001, and used two of the good pistons on the engine I was rebuilding. I used plastigage on each bearing journal and they were all within the specs I found in the Haynes manual. After I got it all back together, the fuel pump on the 2000 didn't work. I decided to take the fuel pump out of the 2001, and found out that they use different fuel pumps. On the 2000 fuel pump, the fuel pressure switch is on top of the the pump. The 2001 has the fuel pressure switch on the tank.
The 2001 pump worked in the 2000 Windstar, but I had a "Fuel Data Error". I assumed this was because the Fuel pressure switch was not plugged in. So, we changed out the fuel tank, using the 2001 tank, fuel lines, electrical connection, and I still get the "Fuel Data Error". I guess the computer is looking for the fuel pressure switch from the fuel pump, and instead it is on the tank.
It was surprising how many things had been changed on the Windstar from 2000 to 2001. Even the coil is in another place on the 2000 that it is on the 2001. The oil pan on the 2000 is steel, and the oil pan on the 2001 is cast aluminum.
It's educational working on two "identical but a year apart" Windstars.
Last edited by DPH; May 9, 2020 at 07:37 PM.
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Joined: Jun 2010
Posts: 16,586
Welcome to the club.
Vehicle manufacturers will incorporate even mid year changes on the same model to update or correct some realized problems. That is why it is so critical to use your VIN and check with a dealership Parts Dept. .. The difference you noticed could be where they incorporated a feedback circuit to tell the PCM whether the fuel pump was or was not getting the correct info or was responding to certain info. Sure makes life interesting.
Vehicle manufacturers will incorporate even mid year changes on the same model to update or correct some realized problems. That is why it is so critical to use your VIN and check with a dealership Parts Dept. .. The difference you noticed could be where they incorporated a feedback circuit to tell the PCM whether the fuel pump was or was not getting the correct info or was responding to certain info. Sure makes life interesting.
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