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#1
05-20-2006, 11:26 PM
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cleaning lower intake mainfold ??
After what was starting to seem like it would be a never ending battle with my 97 windstar stalling i found this forum and found the tip to block of the vacuum hose from the egr and now the van is running better still stalling but not as easily
could someone please give me a step by step on how to clean the lower intake manifold now so that perhaps i can finally resolve the problems with this thing 
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#2
05-21-2006, 09:23 PM
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Re: cleaning lower intake mainfold ??
I have a link to pictures of my '96 3.8L that may help you.
You have to remove the upper intake manifold, being careful of the many vaccum connections on the back side of the upper intake manifold....you will need to be sure to get them all correctly re-connected when you put it back together. A loose vaccum hose will cause rough running, up to and including stalling. The upper intake manifold gaskets are re-usable. The EGR ports are shown in my pictures. They clog just at the end, as the EGR flow joins with the rest of the air flowing in the intake. So the rest of the EGR passages through the lower intake manifold to the EGR valve should be just fine. You can use a vaccum cleaner and a small pic or small poker of some sort to poke the crud loose, and suck it up. You want to keep as much crud as possible from falling on down into the lower intake. Look to see that the IMR plates are not so cruddy as to prevent smooth operation as the close (they will be open with the engine OFF).
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Moderator for Ford Windstar room only Links to my pictures, intended as an aid, not a replacement for, a good repair manual. 1996 3.8L Windstar http://www.flickr.com/photos/4157486...092975/detail/ 2003 Toyota Sienna pictures (not much there yet) http://www.flickr.com/photos/4157486...781661/detail/
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#3
05-22-2006, 01:26 PM
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Re: cleaning lower intake mainfold ??
Well it took me the enitre weekend but its now fixed thanks to wiswind's help the butterfly valves on the entire back bank of the lower intake were gummed up with carbon, thaks to my wifes small fingers and some carb cleaner they are now moving freely and while i was there i cleaned the rest up as best as my fat fingers allowed
the van is now not stalling while in drive it sometimes stalls when backing up if u dont give enuff gas but at least the hesitation in drive is gone and now we can at least get back and forth to work. THANK YOU VERY MUCH WISWIND MY POCKET BOOK AND MY FEET OWE YOU A DEBT OF GRATITUDE 
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