Monday, March 12, 2012

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).

    Click image to see an enlarged view
    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


Click image to see an enlarged view
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

    Click image to see an enlarged view
    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

    Click image to see an enlarged view
    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


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