99 Windstar making clacking noises

[donro]

Due to the typical 140 and 141 error codes that are so common on Windstars, I just replaced my intake manifold gasket, put in the new green positioners in the intake plenum and replaced the upper and lower gaskets on the plenum. I took the fuel injector rail off and replaced the lower "o" rings on the fuel injectors.

Once I got everything assembled, the engine starts and runs but it makes a noise like the clacking of a diesel engine's injectors. The noise increases in frequency as the rpms increase. I suspect that maybe one or several of the injectors did not seat completely.

Does anyone have any recommendations???

[12Ounce]

You may have a vibration between the two plastic pieces that make up the upper intake manifold.

???

If so, many of us have dampened the vibration using sensor-safe RTV.

[donro]

Originally Posted by 12Ounce

You may have a vibration between the two plastic pieces that make up the upper intake manifold.

???

If so, many of us have dampened the vibration using sensor-safe RTV.

Thanks for your reply. I have seen that problem occuring in several threads, however, this is a very sharp sound. I can't imagine that the plenum pieces could produce this type of sound.

[12Ounce]

Frankly, I've never heard the noise ... just added the RTV when broken clips were discovered during intake repairs. You can try pressing down on the upper intake manifold to see if that affects the nature of the sound.

Did you have any reason to move the Camshaft Position Sensor synchronizer?

[donro]

Originally Posted by 12Ounce

Frankly, I've never heard the noise ... just added the RTV when broken clips were discovered during intake repairs. You can try pressing down on the upper intake manifold to see if that affects the nature of the sound.

Did you have any reason to move the Camshaft Position Sensor synchronizer?

12Ounce: I have put a stethescope and I cannot isolate the sound. I suspect that it is a lifter. When I removed the intake manifold some antifreeze went into the engine. I have since changed the oil but the lifter has not charged up again. It definitely is not the plastic upper intake manifold. You mentioned the camshaft position sensor. I am not familiar with that. However, I don't believe that I touched anything similar to that. Thanks for your help.