I've seen the posts on here about the tsb for the po171 and 174 trouble codes. I think i'm going to have to do this procedure on my 1999. Does anyone know where to get the parts to do the procedure, is it something that has to be purchased through the ford dealer in a kit or just the individual parts. thanks.

The best price on the repair parts is on e-bay. Seller ECarOnline has all of the parts for a buy-it-now price of $89.99 + $9 shipping and handling.
- UPDATED FRONT VALVE COVER ASSEMBLY
- NEW PCV & FUEL PRESSURE REGULATOR VACUUM LINES
- NEW THROTTLE BODY, UPPER INTAKE, UPPER INTAKE PORTS & IDLE SPEED GASKETS
- 8 NEW INTAKE ISOLATOR BOLTS WITH UPDATED SEALS

Also look at Millennium Ford @ y2kford.com

Read the TSB for the required parts and their part numbers. Ford does not offer this in a kit form.

Thanks for the info. I guess i need to check my existing vavlve cover first to see if it has the small hole, maybe it has already been done, but i don't think so. I guess even if the valve cover had been changed, that doesn't mean whoever did it, did the isolator bolts too.

sb68 -

I performed the isolator bolt/port seal procedure http://leckemby.net/windstar/windstar01.html on my 2000 Windstar LX 3.8 a few months ago. I bought the parts from my local dealer, based on the part numbers included in the procedure (i.e., it wasn't a kit, just a collection of parts).

However, if I had to do it over again, I would not buy the valve cover.

First, take a look at the comparison of the two valve covers here: http://www.miracerros.com/mustang/pcv_filter.htm. Yes, these are pictures of the Mustang version of the 3.8, but they look exactly the same as the Windstar.

This means budget-sensitive Windstar owners should be able to modify their original valve cover to match the revised cover. You'd probably only need some tin snips (there is one corner of the interior baffle that has a new notch), a pair of pliers (one corner is bent slightly differently) and some reliable way to plug the hole (I'd suggest an appropriate size bolt, with a nylock-style locking nut).

I highly recommend performing the isolator bolt/port seal procedure. If you spend some time reading and paying attention to details, it isn't a terribly difficult DIY job. All of the symptoms I had seen before (pinging, etc.) are now gone; van runs great.

When I did my Isolator bolt fix I did not replace the vacuum fuel regulator because it seemed tight fitting and it can always be done afterwards without disassembly of the intake. I also did not replace the valve cover because I did not (and still do not) believe that it really prevents oil from getting into the PCV system. Again I figured that if I had to do it later I could. I would actually do a mod similar to what Phil suggested first.

I agree that the Isolator bolt/port seal is fairly straight forward repair. A bit time consuming but not too difficult. The link shows some excellent views and is handy to print out and keep with you for reference. I think that removing the cowling will give you better access and do take the opportunity to replace the rear spark plugs while you are in there. (use the correct Motorcraft or Autolites).

Stuff some rags into the intake while fiddling around to prevent something from being dropped in and pay attention to the relatively low torque specs of the isolator bolts.

For an experienced DYI'er I would estimate about 4 to 6 hours and that includes a beer with the neighbour when he comes over to see what you are doing.

thanks for the input. I think you're right, I've already had the cowling off and replaced the rear plugs, but that was before i found out about the tsb. I've saved and printed the info in the link and it doesn't look to be that invoved of a fix.

OK, now i'm confused. I took the pcv valve and grommet out of the valve cover and I cannot see any hole in the baffle as it shows in the tcb link. Does this mean that my van already has the repair done on it as described in the tcb? If so, what could be other causes that could be giving me the error codes? I looked on the valve cover and could not find any tag indicating date of manufacture or anything on the vehicle saying the repair has been done. Is it possible the valve cover had been replaced without the rest of the tcb being done? I bought the van used with about 75,000 on it, it now has about 120,000. any help is greatly appreciated.

Is it possible the valve cover had been replaced without the rest of the tcb being done?

That's the case with my 2000. If the P0171/P0174 codes were only caused by the fuel pressure regulator vacuum line as it was in my case, they might have only replaced that vacuum line and the valve cover.

Is the exterior of your valve cover painted black or is it just an unpainted casting? Supposedly, the redesigned Ford OEM valve cover is an unpainted casting (silverish-color when new; will discolor over time); my original is painted black. I don't know for sure that Ford was consistent about this color coding scheme.

Note that the hole is very difficult to see, even with the PCV grommet out. One recommendation: Just take the valve cover off. It only takes a few minutes, and the gasket is attached to the cover (and therefore reusable). Then compare it to the pictures in the link I posted earlier.

My valve cover is black, but i'm pretty sure i can see in there where the hole is supposed to be according to the link. I was using a very bright led light and i didn't see a hole, it looked completely smooth. However, i think i will take the valve cover off to make sure. thanks.

I suppose we should cover 171/174 causes. These are lean codes detected by the O2 sensors. They are normally reading correctly and in fact when they throw this code (codes) it means that there is a lean condition.

Lean conditions are caused by unmetered air in the intake stream. Unmetered air is air that somehow got in after the MAF sensor. This is normally due to an intake leak (vacuum leak). It could also be a faulty MAF that is reading low. It could even be the O2 seonsors themselves (but I doubt this). Since you have both left and right lean codes it normally indicates a common problem to both banks.

It is possible that your van has had some of the repair done or all of it. It could be that the repair was done using the old style bolts too and they have now deteriorated. The rubber around the bolts have been redesigned and now are green (as opposed to the older black). You could remove the upper intake to have a look. Perhaps you have a leak elsewhere.

Good luck and feel free to keep asking.

Ok, i did the tsb today and now i'm a little confused. When i got the valve cover off, there was no hole in the baffle, but when i pulled the plenum off of the intake, there was a lot of oil in there and it did still have the black isolator bolts. I suppose maybe a previous owner could have had the valve cover replaced and failed to have the rest of the tsb done, but if that's the case would there still be that much oil in there over a long period of time. I also noticed when i took the original pcv valve off that there was oil in it and the tube. My question is how would that much oil have gotten into the intake if it had the newer style valve cover installed? Is it possible oil is getting into the intake from some other source?

You will still get oil into the intake with the new valve cover. However, you will get less oil than you would with the old valve cover.
It has been suggested that one should stick to Motorcraft brand of PCV valve when replacing it, as some aftermarket brands may let too much air pass through.....which would pull more oil. Of course, you want air to be pulled out....because you are trying to pull harmful vapors and moisture out of the crankcase as they can be bad for your engine if not removed. As the vapors cool, they will cause condense into an oily film, which is why there will be some oil present in the intake. The goal of the system is to draw these vapors into the engine and burn them off. However, if there are places for the liquid to collect, then it will collect there, instead of going on into the engine.

Short answer, you want to see some oil, as this is a sign that the PCV system is doing it's job.
Too much oil is not good though.

[QUOTE=jgattian]The best price on the repair parts is on e-bay. Seller ECarOnline has all of the parts for a buy-it-now price of $89.99 + $9 shipping and handling.
-QUOTE]


jgattian,

I found the seller but not the parts. Please provide a link if possible. Thanks.

SMF

Ditto about the oil on the upper manifold spacer: It ain't all bad.

As posted, it is the result of an aggressive PCV system ... will help keep your crankcase clean.

Of course, if there is extra air admitted to the intake manifold due to leakage ... expect some gunk to build up inside the manifold.

ALSO ... if the air filter is allowed to get loaded up: expect excessive oil to be pulled out of the crankcase.

[QUOTE=jgattian]The best price on the repair parts is on e-bay. Seller ECarOnline has all of the parts for a buy-it-now price of $89.99 + $9 shipping and handling.
-QUOTE]


jgattian,

I found the seller but not the parts. Please provide a link if possible. Thanks.

SMF
http://cgi.ebay.com/ebaymotors/99-02-WINDSTAR-INTAKE-MANIFOLD-VALVE-COVER-REPAIR-KIT_W0QQcmdZViewItemQQcategoryZ36474QQitemZ8047185 615QQrdZ1QQsspagenameZWDVW

He has removed the listings for some reason. The repair parts listings have been on constantly for the last 6+ months.

First of all, I want to thank everyone on this site about the information about this TSB repair. I own a 1999 Windstar SEL and I had these codes, did the required TSB work, and the codes cleared (about 2-3) weeks ago. I have been suspicious about a noise I am hearing under the hood though. I do not recall hearing it before the repair but that does not mean much seeing as I was not really paying attention. I am hearing what sounds like a vacumm leak around or inside the plenum. I have sprayed its perimeter and hoses with throttle body cleaner while it is running with no change in idle. It is only apparent when i apply throttle quickly while the hood is opened. I put my ear to the top cover of the plenum and can hear it there stronger. Is this normal with the plastic plenum material? Would this sound be normal had the upper intake been made out of alluminum. Is what I am hearing just the air being sucked through the upper intake into the lower? I am just concerned that something else is wrong. I also observed something odd while giving the van throttle. It appears that the upper intake plenum swells slightly when throttled up, almost as if it is a breathing lung. It may be the fumes from the carb cleaner, but who knows. HA HA. The van runs great and there is no CEL. Does anyones else van sound like this to with the hood open and giving it throttle? Any insight or similar noises may hoppfully put my mind at ease. Thanks again.

I have a 2001 3.8L and my mechanic is telling me there is a leak on the lower intake manifold where the small rod goes through to the dual plane. He tells me that I'll have to replace the entire manifold ($325) because he knows of no repair for that seal.
Has anyone heard of a repair for this? Seems nonsense to have to replace the entire manifold because of a seal which can't cost more than 5 bucks!

First of all, I want to thank everyone on this site about the information about this TSB repair. I own a 1999 Windstar SEL and I had these codes, did the required TSB work, and the codes cleared (about 2-3) weeks ago. I have been suspicious about a noise I am hearing under the hood though. I do not recall hearing it before the repair but that does not mean much seeing as I was not really paying attention. I am hearing what sounds like a vacumm leak around or inside the plenum. I have sprayed its perimeter and hoses with throttle body cleaner while it is running with no change in idle. It is only apparent when i apply throttle quickly while the hood is opened. I put my ear to the top cover of the plenum and can hear it there stronger. Is this normal with the plastic plenum material? Would this sound be normal had the upper intake been made out of alluminum. Is what I am hearing just the air being sucked through the upper intake into the lower? I am just concerned that something else is wrong. I also observed something odd while giving the van throttle. It appears that the upper intake plenum swells slightly when throttled up, almost as if it is a breathing lung. It may be the fumes from the carb cleaner, but who knows. HA HA. The van runs great and there is no CEL. Does anyones else van sound like this to with the hood open and giving it throttle? Any insight or similar noises may hoppfully put my mind at ease. Thanks again.


I have always heard what I consider to be an unusually loud vacuum sound but I accepted it as most likely normal. (though I could be wrong).

Isn't the intake too rigid to flex? Is it collapsing? If so this would seem to suggest that the intakes to the cylinders are demanding more than the intake will allow. I can't see that occuring at relatively low RPMs unless you have some restriction in the intake. Even a clogged filter.

OK, I did the TSB about 2 years ago and got the new valve cover, and reflash. I get no codes but still seems to have some hesitation and oil pool up in the upper intake. I also just recently purchased a smoke machine and found that when hooked up, I get smoke from under the EGR housing (not the connection to engine point), from that button thing on top the IAC valve and more than I would like from around the IMRC bushings. Should I be getting smoke from these places as described?

2000 LX, 3.8l

[QUOTE=smf]
http://cgi.ebay.com/ebaymotors/99-02-WINDSTAR-INTAKE-MANIFOLD-VALVE-COVER-REPAIR-KIT_W0QQcmdZViewItemQQcategoryZ36474QQitemZ8047185 615QQrdZ1QQsspagenameZWDVW

He has removed the listings for some reason. The repair parts listings have been on constantly for the last 6+ months.

Another seller has the repair kit listed for sale on eBay.
http://cgi.ebay.com/ebaymotors/FORD-WINDSTAR-VALVE-COVER-REPAIR-KIT-99-03-3-8-ALL-NEW_W0QQcmdZViewItemQQcategoryZ33627QQitemZ8052352 562QQrdZ1QQsspagenameZWDVW

I'll Be dog!!! That is a Great price. If anybody need to do this job.. This is a steal.. Even comes with the valve cover. You may have an updated one already. But new is new and I paid that much for the isolator bolts and port seals alone> With a discount.. Thanks for posting this This could help someone save a lot of money even with the 12.75 shipping its a bargin.