Need advise on Isolator/Intake repair..

[JoeJWill]

I checked today for the hole in the 5 o'clock position inside the valve cover and could not see one. I have the black valve cover; most have described the replacement as a silver cover. I have not taken off the intake cover to see if a previous repair has been done. I guess that will be required to be for sure.
1. Can someone tell me exactly where the knock comes from? What is hitting?
2. I can find no external air leak causing the 171/174. Is the leak internal? And will the isolator bolt correct the CEL code? Other than the knock and the light, the van runs smooth.
thanks, JoeJWill
JoeJ

[lewisnc100]

Your Windstar is a 2001 so it came from the factory with the redesigned valve cover in black. The replacement silver valve cover was for the 99-2000 year Windstars.

[12Ounce]

If you have the infamous "baffle knock", it is inside the upper intake manifold ... that plastic cover thing that is to top of the engine. It's acually a two-piece affair ... and its the inside piece that breaks free and starts vibrating. The intake "upper" is attached to the intake "spacer" (the plastic piece that the throttle body is attached to) with 14, or so, screws around the perimeter.

The leaks causing 0171 and 0174 are often caused by the "isolator bolts" (a bolt with built-on seals) that attach the "spacer" to the metal "lower". You will not see the bolts until you remove the "upper".

[garync1]

I would go ahead and replace the upper intake FMC 2F2Z9424AA 151.75 dealer retail price is 159.00 I found one place for 129.00 but would had to wait on shipping. It looks a little different such as the top seems to be a little more sloped.. the baffle is welded in.. well plastic welded.. My intake looked a little rough on the inside plus the baffle had a crack and a chip. The chip was my fault.. I started it up this morning on a cols start and no knock....Take the cowl off it will make the job eaiser. One plug holds the wiper in so be carefull.

[DRW1000]

Just to add to 12Ounce's response.

The TSB states that it is to be performed if the vehicle has 171/174 codes and there are no other drivability concerns. (I think yours qualifies).

Different years require different degrees of the TSB. As was pointed out your may have the updated valve cover.

All of the years covered require the Isolator bolts. It is the deteriorization of the rubber that causes the leaks. There are other ways to get those 2 codes but sooner or later the bolts will deteriorate. The Isolator bolts have been re-designed with a different type of rubber. The TSB states to relace the port seals as well. I personally do not feel this is necessary an a good cleaning of the top of the lower intake should be sufficient but to be on the safe side you should replace them. If your vaccum regular hose is loose replace it as well. (you can check this without disassembling anything.). The TSB calls for a new valve cover. It sounds like you may have the updated version. I did not but I did not (asnd still don't) think it is necesaary.

I have a lot of experience as a DYI and it took me about 6 hours or so. I took my time. It is a straighforward job and I would think that anyone who has done drum brakes or something similar should have no problems. Print out the link that shows the step by steps (can't remember who posted it). They are excellent instructions. If you are going to do it yourself then take your time, plug the intake holes when you get the top off to ensure nothing falls in. When you get the top off then you will see the rattling piece that 12ounce has mentioned.

Good luck.

[garync1]

Joe on the 2001 you are ok on the valve cover all you will need is the isolator bolts. FMC 3F2Z9S479AA qty 8 72.08. Port seals/gaskets is FMC XF2Z9H486AA qty 6 18.96 I paid 97.41 tax included for all if your dealer is higher than this I got a web site you can go to.. Also I do trust most opions on here as far as the intake issue. I would replace it. you do have a great deal of miles on it. the part number is FMC 2F2Z9424AA 151.75 AT MY LOCAL DEALER .THE retail is 159.00.
You also want to check the vacuum lines like stated on the tsb for leaks mine were ok.. This site was were i was going to order from but my dealer was resonable enough. I think they have the same intake for 129.00 but check with shipping charges. hope this helps..

http://www.newfordparts.com/

[JoeJWill]

Thanks so much!!! Hopefully, I will start this week if the dealer has the parts.
Should any of the gaskets/seals be reused?
Joe

[garync1]

Originally Posted by JoeJWill

Thanks so much!!! Hopefully, I will start this week if the dealer has the parts.
Should any of the gaskets/seals be reused?
Joe

Not for the intake, but the throtle body will be fine other than that there no other seals you will run into.. just port seals need replacing . just make sure you inspect the vacuum line one for the throttle body back side 1 for the brake booster and a unit line not quite sure what that was, it had 2 hoses pluged in together to the lower intake plenum and a plug you need to unplug.all this is on the backside of the intake.

[DamnDummy]

What does one do if you've snapped off two isolator bolts by over-tightening? Have I made a bad situation many times worse?

[Windstartled]

Originally Posted by 12Ounce

Wiswind, that is a good link.

BTW, my Haynes was written for the '95 thru '01 models.

I would like to have a Haynes like yours, mine was likely published later and covers even the Freestar. That is not a plus, it just adds to confusion when it covers more models. Ideally Haynes should have published separate manuals: one for the 95-98's which are significantly different from the 99-03's, and one for the 99-03's and the Freestar which are very similar.