OEM 2000 Ford Windstar Intake Manifold

2000 Ford Windstar Intake Manifold Parts Q&A

• Q: How to service and repair the upper intake manifold on 2000 Ford Windstar?

  A: The service process for upper intake manifold begins by disconnecting safety cables followed by air cleaner assembly disassembly and separation of air cleaner outlet tube. First drain a portion of the engine coolant system then release fuel pressure from the system. Begin by taking out the cowl assembly followed by setting the wire harness to the side. Separate the retainers before disconnecting all necessary hoses and vacuum tubes that include both coolant hoses and IAC and TP sensor and differential pressure feedback sensor electrical connectors. The removal begins with disconnecting the accelerator and speed control cables before the throttle body can be taken out by removing its bolts. The differential pressure feedback sensor must be set aside before removing its attached tube by disconnecting the nuts. Detach the EGR vacuum tube along with the EGR tube from its connection by unscrewing the nut before removing the generator bracket through the nut and bolt removal steps. The first step should be to unfasten upper intake manifold bolts and stud bolts before taking out the intake manifold gasket. Before setting down the upper intake manifold all sealing surfaces need cleaning before placing a new intake manifold gasket. After fitting the three bolts and three stud bolts install them with a two-step torque procedure at 20 Nm (14 ft. lbs.) first then 25 Nm (18 ft. lbs.). After bracket replacement install the generator while securing the EGR tube by tightening the nut. Connect all vacuum tubes with hoses alongside the differential pressure feedback sensor while placing the sensor correctly and fastening its bolts. Before placing the throttle body, install a new gasket and fasten it with bolts before reattaching accelerator and speed control cables. Reconnect all components in the engine wire harness that include the throttle position sensor as well as the differential pressure feedback sensor and the idle air control (IAC). All hoses and coolant hoses should be attached first followed by vacuum tubes. Next install wire harness retainers on their positions. The last step of the cleanup includes reinstalling the cowl assembly before you refill the engine coolant system and install the air cleaner assembly and air cleaner outlet tube and finally reconnect the battery ground cable.