Windstar 2000 SEL Air Intake Plenum. Please, need advice ASAP.

Guys,
I can hear clicking noise around Air Intake Plenum cover area. When I start my van it kind of loud, then later it comes and goes. Noise is not metal more kind of plastic hit plastic noise.
I took the air intake plenum cover out. (please see pictures)
http://www.nhcg.us/images/cars/pic1.JPG
http://www.nhcg.us/images/cars/pic2.JPG

That thing that clips inside cover (see picture 2) is little bit loose.
Does anybody know how tight it suppose to be? Do I need to replace the whole air intake plenum?

Please help ASAP.

Thanks in advance.

Guys,
I can hear clicking noise around Air Intake Plenum cover area. When I start my van it kind of loud, then later it comes and goes. Noise is not metal more kind of plastic hit plastic noise.
I took the air intake plenum cover out. (please see pictures)
http://www.nhcg.us/images/cars/pic1.JPG
http://www.nhcg.us/images/cars/pic2.JPG

That thing that clips inside cover (see picture 2) is little bit loose.
Does anybody know how tight it suppose to be? Do I need to replace the whole air intake plenum?

Please help ASAP.

Thanks in advance.


I've never had a 2000 3.8 apart. However, if it's loose I'd tighten it up. Is is sheet metal? It's not a gasket is it? It's probably just a spash deflector for oil. (just guessing from the pic.)

Regards

Dan

I've never had a 2000 3.8 apart. However, if it's loose I'd tighten it up. Is is sheet metal? It's not a gasket is it? It's probably just a spash deflector for oil. (just guessing from the pic.)

Regards

Dan

Thanks for your post,

I don't think I can tight it up. The loose part is that plastic part that on the first picture sit's inside and on the second picture is out.
It's connected to the plastic cover by two plactic clips (you can one of them on second picture).

Thanks for your post,

I don't think I can tight it up. The loose part is that plastic part that on the first picture sit's inside and on the second picture is out.
It's connected to the plastic cover by two plactic clips (you can one of them on second picture).


Hello

I would take the intake to a Ford dealer parts department or service and talk to a mechanic and see if you can get their opion on it.

The guys that work on these things every day should be able to help you out.

Do you have a book on your van? If you don't goto the Library and check one out.

Regards

Dan

If I remember correctly when I had mine all apart I noticed that it is somewhat floating and not really tight. I doubt that it will matter performance wise.

I have had success using sensor-safe RTV sealant as an "adhesive" between these plastic parts. ... seems to dampen the vibrations.

Here is what I did, I do not know how long it will last but here goes.

I simply heated up the tabs with the old blow torch and pried them out a little, so when it snaps in it is very tight.

Hopefully this will last.

This is just my 2 cents.

By the way thanks all of you for the information on this site. I just completed the 171 and 174 Code fix and the P0401.

I would definitely recommend replacing the spark plugs while everything is apart. I would also recommend taking off the cowl.

Thanks again!!!

I don't know if this would be the same problem/noise you're hearing but I had to have the gasket replaced on my wife's 2000 upper plenum. I had a tapping noise (for lack of a better description) it almost sounded like a valve tappet knock from an old Ford engine.

From what the mechanics I take my nissan to told me is that these go out at 70~75k miles religiously.

On a side note: They also said, at that point, they would go ahead and change the sparks plugs b/c having the plenum & stuff off makes it easier to change the back 3 plugs.

Guys,
(please see pictures)
http://www.nhcg.us/images/cars/pic1.JPG
That thing that clips inside cover (see picture 2)

where are these pictures located? I'd like to view them.:naughty:

I Would use the sensor safe RTV as mentioned to fix the problem rather than buy another one, just use a small amount and let it dry before re-installing everything. Good luck.

To further the argument of using RTV, let me offer another choice ....

I first used the RTV as an adhesive to augment the plastic clips that hold the inner-baffle in place ... worked fine. But what it did not do was have any impact on ... was the tendency for the EGR jets to plug up.

So, the "OTHER" choice is the following: (A) First destroy, and remove, all of the clips that hold the inner-baffle to the outer-shell. Clean up all the part edges. (B) Stick the inner baffle, not to the upper shell, but to the lower plastic "spacer". Use RTV as a glue to hold the plastic parts together, totally sealing the "barrels".

The above action stops LIQUID oil, recovered from the crankcase thru the PVC system, to drip down onto the EGR jets. The recovered oil is now forced to be air-lifted into the air stream as a MIST ... doing no harm to the jets, and actually helping the upper cylinder area.

This whole business only works on the models that have the removable inner part. 1999 - 200?

Here is a video with the engine and noise. I spoke to my neighbor, he stated the noise and vibration can be from anywhere, so next I'm doing a valve compression check, will post results here.

If nothing happens, I'll take the front valve cover off after that!

http://youtu.be/01T1R2Aecdg

What do you think?