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 1793 (ENGINE MECHANICAL - 2.5L (HYBRID))ASSEMBLYENGINEINTAKE MANIFOLD
1999 Ford Windstar Base, Van Cargo, 3.8 4
Intake Manifold
1999 Ford Windstar Base, Van Cargo, 3.8 4SECTION Intake Manifold
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.
ITEM DESCRIPTION TABLE
| Item | Part Number | Description |
|---|---|---|
| 1 | 9288 | Fuel supply tube |
| 2 | 8K556 | Coolant outlet |
| 3 | 9D475 | EGR valve |
| 4 | 9F991 | Electronic Throttle Body (TB) |
| 5 | 6051 | Cylinder head gasket |
| 6 | 6010 | Cylinder block |
| 7 | 12A699 | Knock Sensor (KS) |
| 8 | 9424 | Intake manifold |
| 9 | 9439 | Intake manifold gasket (4 required) |
| 10 | 8A582 | Coolant hose |
| 11 | 6049 | Cylinder head |
| 12 | 9F593 | Fuel injector (4 required) |
| 13 | 9H487 | Fuel rail |
| 14 | - | Fuel rail insulator |
NOTE:
Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools or severe engine damage can occur.
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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.