How to Replace Intake Manifold on Ford Windstar?

The details to replace intake manifold are as follows :---


Intake Manifold
REMOVAL & INSTALLATION  instructions are mentioned below:----

3.0L Engine

1. Remove or disconnect the following:
   
   NOTE

   The lower intake manifold may be removed with the fuel injection supply manifold and fuel injectors in place as an assembly.
   
   
   
   
   Negative battery cable

   Coolant

   Crankcase ventilation tube from the valve cover

   Air cleaner inlet and outlet tubes

   Fuel system pressure

   Fuel line safety clips and disconnect the fuel lines

   Vacuum lines

   All electrical wiring attached to the intake manifold

   All control cables

   Radiator and heater hoses

   Alternator brace

   EGR tube and EGR valve

   Fuel charging assembly

   Ignition wires

   Ignition coil pack

   Camshaft position sensor

   Valve covers

   No. 3 intake valve pushrod
   
   
   
   
   Lower intake manifold retaining bolts using a Torx® head socket. Use a soft-faced mallet to tap the manifold upward if it is hard to remove.

   Intake manifold

To install:

1. Thoroughly clean all gasket mating surfaces on the intake manifold and cylinder head.
   
   WARNING

   When cleaning the cylinder head gasket surfaces, lay a clean cloth in the valve tappet area to prevent any particles from entering the oil drain-back area.
2. Apply a 0.25 in. (6mm) bead of silicone rubber sealant to the intersection of the cylinder block and cylinder head at the 4 corners of the intake manifold.
3. Install the intake manifold gaskets, aligning the intake gasket locking tabs to provisions on the head. Install the front and rear intake manifold end seals and secure with retainers.
4. Install or connect the following:
   
   
   Intake manifold

   Intake bolts Nos. 1, 2, 3, and 4. Tighten by hand.

   Remaining intake bolts and tighten all bolts in sequence to 15-22 ft. lbs. (20-30 Nm). Tighten again in sequence to 20-23 ft. lbs. (26-32 Nm).
   
   

   

   

   Fig. Intake manifold bolt torque sequence-3.0L engine

   No. 3 intake valve pushrod and rocker arm

   Valve covers

   Camshaft position sensor

   Coil pack and ignition wires

   Fuel charging assembly, and tighten the bolts to 71-106 inch lbs. (8-12 Nm)

   EGR tube and EGR valve

   Alternator brace

   Radiator and heater hoses

   Control cables

   All electrical wiring

   Vacuum lines

   Fuel lines and install the fuel line safety clips

   Air cleaner inlet and outlet tubes

   Crankcase ventilation tube
5. Fill and bleed the engine cooling system.
6. Connect the negative battery cable.
7. Start the engine and check for leaks.

3.8L Engines
Lower Manifold

Fig. Lower intake manifold and related components-3.8L engine

1. Remove or disconnect the following:
   
   NOTE

   The lower intake manifold is sealed at each corner with sealer. To break the seal it may be necessary to pry on the front of the intake manifold with a prybar. If it is necessary, use care to prevent damage to the machined surfaces.
   
   
   
   
   Coolant

   Upper intake manifold

   Water bypass hose from the heater water outlet tube

   Bypass hose from the lower intake manifold

   Fuel system pressure

   Electrical wiring harnesses

   Fuel injectors and fuel charging assembly

   Vacuum motor and bracket assemblies

   Valve assembly and linkage from the IMRC lever and bushing by using a prytool

   Tube retaining bolts

   Old bushing from the lever

   EGR valve and adapter

   Lower intake manifold retaining bolts
   
   
   
   
   Lower intake manifold

To install:

1. Thoroughly clean all gasket mating surfaces.
   
   NOTE

   When using silicone rubber sealer, assembly must occur within 15 minutes after sealer application. After this time, the sealer may start to set up and its sealing effectiveness may be reduced.
2. Install or connect the following:
   
   
   New bushings into the IMRC levers

   Apply a 3mm bead of RTV silicone sealer at each corner where the cylinder head joins the engine block
   
   

   

   

   Fig. Lower intake manifold bolt torque sequence-3.8L engine

   Front and rear intake manifold seals

   Lower intake manifold into position on the cylinder block, using new gaskets

   Apply pipe sealant to the intake bolts and install in their original locations. Tighten in sequence to 71-106 inch lbs. (8-12 Nm).

   EGR valve and adapter

   IMRC vacuum motors, and tighten the retaining bolts to 71-106 inch lbs. (8-12 Nm)

   Fuel injectors and charging assembly. Tighten retaining bolts to 71-97 inch lbs. (8-11 Nm).

   Water bypass tube to the lower intake manifold. Tighten the retaining bolts to 71-97 inch lbs. (8-11 Nm).

   Water bypass tube hose to the outlet tube and tighten the hose clamp securely

   Electrical wiring harnesses

   Vacuum lines to the IMRC motors

   Upper radiator hose to water hose connection and tighten the hose clamp securely

   Upper intake manifold
3. Fill and bleed the cooling system.
4. Start the engine and check for leaks.

Upper Intake Manifold (Plenum)

1. Remove or disconnect the following:
   
   NOTE

   Keep the intake manifold bolts in order, so they can be installed in their original positions.
   
   
   
   
   Air cleaner outlet tube

   Accelerator cable and speed control actuator cable at the throttle body

   Accelerator cable bracket and position it aside

   Vacuum lines

   Necessary electrical harnesses

   Crankcase ventilation tube from the PCV valve

   Throttle body

   Idle air control valve

   Intake manifold retaining bolts, noting their positions
   
   
   
   
   Upper intake manifold

To install:

1. Inspect the intake gasket to ensure the seals are completely installed in the manifold groove and the seals show no signs of damage.
2. Install or connect the following:
   
   
   Intake manifold and tighten the bolts to 71-106 inch lbs. (8-12 Nm) in the sequence shown
   
   

   

   

   Fig. Upper intake manifold bolt torque sequence-3.8L engine

   Idle air control valve

   Throttle body

   Crankcase ventilation tube to the PCV valve

   Electrical harnesses

   Vacuum lines

   Accelerator cable bracket and tighten the bolts to 71-106 inch lbs. (8-12 Nm)

   Accelerator cable and speed control actuator cable at the throttle body

   Air cleaner outlet tube

This details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html