Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSFORD1999WINDSTAR BASE, VAN CARGO, 3.8 4REPAIR AND DIAGNOSIS (SINGLE PAGE)EXTERNAL PAGESDIFFERENT CARSECTION 1791 (ENGINE MECHANICAL - 3.0L (4V))IN-VEHICLE REPAIRUPPER INTAKE MANIFOLDINSTALLATION
1999 Ford Windstar Base, Van Cargo, 3.8 4
Upper Intake Manifold: Installation
1999 Ford Windstar Base, Van Cargo, 3.8 4SECTION Installation
WARNING: This page is about a different car, the 2010 Mercury Milan and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
- Clean and inspect all of the sealing surfaces of the upper intake manifold.NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
- Position the upper intake manifold and install the 7 bolts.
- Tighten the bolts in 2 stages in the sequence shown below.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees.
NOTE: Install new upper intake manifold gaskets. - Tighten the bolts in 2 stages in the sequence shown below.
- Install the 2 upper intake manifold support bracket bolts.
- Tighten to 10 Nm (89 lb-in).
- Connect the MAP sensor electrical connector and attach the wiring retainer.
- Connect the PCV tube to the upper intake manifold.
- Attach the engine control wiring harness retainer to the upper intake manifold.
- Connect the EVAP
tube-to- EVAP
canister purge valve quick connect coupling and the brake booster vacuum tube to the upper intake manifold.
- Attach the fuel tube and EVAP tube-to- EVAP canister purge valve tube retainer to the upper intake manifold.
- Connect the EGR valve electrical connector and attach the wiring retainer.
- Connect the EVAP canister purge valve electrical connector.
- Connect the electronic throttle control electrical connector.
- Install the EGR tube fitting to the EGR valve.
- Tighten to 40 Nm (30 lb-ft).
- Install the battery. For additional information, refer to REMOVAL AND INSTALLATION .
- Install the ACL outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION .
RENDER: 1.0x
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.