1995 Model Intake Repairs

[BJI]

After reading many posts about CEL codes for the 3.8L engine. I was wondering if these repairs are the same for all model years? I am about ready to do all the intake repairs, valve cover etc. I plan on using the repair that was posted with all the pictures of the repairs on this site but I basically need to know if that also applies to the 1995 model Windstar. I am assuming that if its a 3.8L than that information covers all model years right? Thanks in advance. BJI.

[12Ounce]

Beware! There have been a lot of design changes during the years ... quite a number of changes in the intake manifold.

What codes do you have?

[wiswind]

The 1995 has a completely different intake manifold.
They went to the black nylon upper intake manifold in 1996, and changed to a different design black upper intake manifold in 1999.....the 1999 and newer manifold is the one in the pictures....and the only one that the TSB for the isolator bolts and the seals applies to.
The change of front valve cover due to a problem with a baffel, is for the 1999 and 2000 years, then they had a correct one from the factory.
You verify the correct valve cover by removing the PCV valve, and shining a light down the hole.....if you cannot see a hole in the baffel that is visible down the PCV hole, you have the good valve cover.
I am not sure on the 1995, but my '96 has the PCV valve on the rear valve cover....the problem that they had with the valve cover was when they moved it to the front.

If you are getting the lean codes that are mentioned in the TSB, look for vaccum leaks.
But your causes would be different......look for loose, or damaged vaccum lines, dirty MAF (can be cleaned with non-residue electronic cleaner).
Also verify that the line from the oil breather to the air intake are intact.

[BJI]

Originally Posted by 12Ounce

Beware! There have been a lot of design changes during the years ... quite a number of changes in the intake manifold.

What codes do you have?

I went to Autozone and they said they could only read 96 and newer cars but I suspect that I have the "common ones". I will be going to my locall mechanic who I know can read them. He read them last fall and said there were a "bunch" and they had to do with vaccum leaks. Also I stupidly forgot to mention that I have had the engine replaced due to head gasket faliure (twice). Once at 60k miles which ford payed for and then the second time at 107k miles which I paid for and replaced the engine. That was in Feb 2001. I looked for the hole in the PCV valve opening (front valve cover) and did indeed see the hole at the 5 oclock position. The engine replacement was done through the local ford dealer. (I know that was pretty dumb). If I can get over this fix I hope to keep this thing since I have put money into the suspension tires brakes etc. Problem with me is I have to clear these codes to get the EPA sticker required by our county before I can get the registration renewed. So what year engine do I have 1995 or 2001 or is there a serial number I need to check? Thanks to you and wiswind.

[wiswind]

If you have the aluminum upper intake manifold, and it is a 3.8L, you have the '95 engine.
I am not familiar with the '95......
Getting the failure codes read will be a big step in solving the issues. One problem can cause multiple codes.
I am not sure if the '95 was OBDII or not.
Ask your mechanic, if it is OBDII, then they can read the codes at autozone. All cars had to be starting in 1996, but some were before that. I remember someone posting that the '95 was as well, but that is all I know.

[BJI]

Originally Posted by wiswind

If you have the aluminum upper intake manifold, and it is a 3.8L, you have the '95 engine.
I am not familiar with the '95......
Getting the failure codes read will be a big step in solving the issues. One problem can cause multiple codes.
I am not sure if the '95 was OBDII or not.
Ask your mechanic, if it is OBDII, then they can read the codes at autozone. All cars had to be starting in 1996, but some were before that. I remember someone posting that the '95 was as well, but that is all I know.

Thanks very much to you and 120unce. You have been very helpful. This answers alot of questions. I will post back and let you know what I find out. BJI

[BJI]

Found out I had codes P1400 and P1407. Replaced the DPFE sensor. Drove for about 3 or 4 cycles and the CEL went out on its own. Idles much better and no the CEL light is not burned out. It checks good on start up. Thanks for all the help. Bought a code reader too. Love that thing. Have 3 cars hope it pays off.