Help with Windstar Intake

9986paulk · October 25th, 2009, 08:03 PM

I have my Windstar almost all put together. I ended up just deleting the EGR because the pipe snapped off about a foot from the headers while I was trying to cut it. First question, Can I use my X-Cal 3 to turn off my EGR? Ok, the second part...what do I do with the PCV hoses? Do I use a tee to run the 2 sides together then into the intake tube? And what is the small vacuum hook-up on the back drivers side of the intake manifold(windstar)? And the one up in front of the coil pack? Thanks for all help!

6er_w/a_Vengance · October 26th, 2009, 01:47 AM

never installed one...but i do have a handy link for ya...

Windstar Manifold HOW TO - V6Power Messageboard

9986paulk · October 26th, 2009, 10:34 PM

Well, OK I got everything installed and ready to go. I cut a pipe and used some rubber connectors to make the intake pipe still go into the fenderwell(though it doesn't look very nice with 2 different colored connectors and pipes, but it does eliminate one 90 degree bend). But when i start it I have this very high pitched whining noise, that I'm positive is a vacuum leak around the throttle body or the IAC port underneath where it goes into the manifold. If anyone else has had the problem please help. We took off the belt to make sure it wasn't any accessory, and it wasn't. And still if anybody knows how I can turn off the EGR with my X-Cal 3, let me know. I have the tune for the manual transmission, but didn't swap it out yet so I'm stuck with the auto and I don't want to pay $59 for something that I'm only going to need for a little while. Thanks again everyone.

WLJohnson05 · October 27th, 2009, 12:15 AM

Originally Posted by 9986paulk

Well, OK I got everything installed and ready to go. I cut a pipe and used some rubber connectors to make the intake pipe still go into the fenderwell(though it doesn't look very nice with 2 different colored connectors and pipes, but it does eliminate one 90 degree bend). But when i start it I have this very high pitched whining noise, that I'm positive is a vacuum leak around the throttle body or the IAC port underneath where it goes into the manifold. If anyone else has had the problem please help. We took off the belt to make sure it wasn't any accessory, and it wasn't. And still if anybody knows how I can turn off the EGR with my X-Cal 3, let me know. I have the tune for the manual transmission, but didn't swap it out yet so I'm stuck with the auto and I don't want to pay $59 for something that I'm only going to need for a little while. Thanks again everyone.

take some brake cleaner, spray it on the hose connections. also did you have the iac shaved on the top of the intake?

9986paulk · October 27th, 2009, 08:26 AM

yea i have the iac shaved, it's a kit from VAP.

WLJohnson05 · October 27th, 2009, 10:57 AM

Originally Posted by 9986paulk

yea i have the iac shaved, it's a kit from VAP.

ok, well try what i said, just take some brake cleaner (with the motor running) and spray it around the vacuum connections. if the motor stutters when you do that then there's your leak.

9986paulk · October 27th, 2009, 08:08 PM

Alright I have the problem almost solved. I just did the old soap and water thing because I couldn't find the brake cleaner. And it was the throttle body gaskets. I just re-assembled it with silicone gasket maker and that stopped it, but I only did one side of the throttle body spacer. Most of the whistle is gone, and I know the problem. I got to take it out for a ride tonight too, and it definitely has more off the line and, well, everywhere. The only thing I noticed was a little softness for the 1st 1/4 inch or so of gas pedal, even though the throttle body does open all the way. And I think I saw something about using a hose somewhere around the pedal to get rid of that feeling. If anyone else knows, let me know. I'm going to try and get some pics up tomorrow. Thanks for the help. Oh and one other fairly significant difference...the exhaust. It definitely is deeper and quite a bit louder at wot.

WLJohnson05 · October 27th, 2009, 08:17 PM

Originally Posted by 9986paulk

Alright I have the problem almost solved. I just did the old soap and water thing because I couldn't find the brake cleaner. And it was the throttle body gaskets. I just re-assembled it with silicone gasket maker and that stopped it, but I only did one side of the throttle body spacer. Most of the whistle is gone, and I know the problem. I got to take it out for a ride tonight too, and it definitely has more off the line and, well, everywhere. The only thing I noticed was a little softness for the 1st 1/4 inch or so of gas pedal, even though the throttle body does open all the way. And I think I saw something about using a hose somewhere around the pedal to get rid of that feeling. If anyone else knows, let me know. I'm going to try and get some pics up tomorrow. Thanks for the help. Oh and one other fairly significant difference...the exhaust. It definitely is deeper and quite a bit louder at wot.

yea thats a simple little mod. just need a little piece of plastic tubing and some tiny hose clamps. give me a minute and ill find the mustangworld writeup on it

edit: here it is
Mustangworld - 99 - 00 Gas Pedal Adjustment tip

just pull the slack out of the cable and cut the spacer to that slack length...leave a little bit though so you wont be pulling on the cable at idle. just cut the side of the spacer open lengthwise and slide it over the cable. then put two clamps on it and tighten it up good. then you should be good to go

9986paulk · October 27th, 2009, 08:48 PM

Thanks, that's exactly what I was looking for.

9986paulk · October 27th, 2009, 09:07 PM

And another good thing...which really wouldn't be much of a problem anyway, is that its not throwing any codes for the EGR being gone. Not yet at least. Where can I get the block off plug for the headers? Until I get it, I'm just going to heat up whats left of the pipe with a torch and squeeze it together to stop the exhaust leak sound and all that crap from blowing around in the engine bay.

WLJohnson05 · October 27th, 2009, 11:46 PM

Originally Posted by 9986paulk

And another good thing...which really wouldn't be much of a problem anyway, is that its not throwing any codes for the EGR being gone. Not yet at least. Where can I get the block off plug for the headers? Until I get it, I'm just going to heat up whats left of the pipe with a torch and squeeze it together to stop the exhaust leak sound and all that crap from blowing around in the engine bay.

dont do that, just go to a nuts and bolts place and get a cap. someone here will know the size, i cant remember at the moment...i want to say 2 inch, but thats just a shot in the dark.

9986paulk · October 29th, 2009, 04:50 PM

So does anyone know on that? The size of the plug/bolt?

9986paulk · October 29th, 2009, 06:57 PM

Oh and I figured out why the pedal was "squishy". It didn't have to do with adjusting the pedal, it was the throttle body. Right where the extension arm joined the throttle body shaft, it wiggles a little less than a half an inch, which it moves when the pedal is pressed before there is a throttle response. Other than that, seems good.

9986paulk · October 30th, 2009, 10:54 PM

Here's a pic of it installed. its not the best quality, but it'll do. I like how it looks and sounds way better. It even somehow made my cold start problem a little better, not sure why on that.

Ticket-Me-Yellow · October 30th, 2009, 11:00 PM

Hey ive seen that before! Looks very nice!

October 25th, 2009, 08:03 PM	#1
9986paulk Regular 1999 Mustang V6 Join Date: Dec 2008 Location: Youngstown Posts: 165	Help with Windstar Intake I have my Windstar almost all put together. I ended up just deleting the EGR because the pipe snapped off about a foot from the headers while I was trying to cut it. First question, Can I use my X-Cal 3 to turn off my EGR? Ok, the second part...what do I do with the PCV hoses? Do I use a tee to run the 2 sides together then into the intake tube? And what is the small vacuum hook-up on the back drivers side of the intake manifold(windstar)? And the one up in front of the coil pack? Thanks for all help!

October 26th, 2009, 01:47 AM	#2
6er_w/a_Vengance Sonic Blue FTGDMFW!!! 2004 Mustang v6 10.73 1/8th mile Join Date: Apr 2007 Location: Portland, TN Posts: 3,560	never installed one...but i do have a handy link for ya... Windstar Manifold HOW TO - V6Power Messageboard __________________ 2004 Mustang 3.9 v6 K&N - True Dual Thrush Welded Exhaust - 5k HIDs - Show car shine 24/7 Fuckers

October 27th, 2009, 08:08 PM	#7
9986paulk Regular 1999 Mustang V6 Join Date: Dec 2008 Location: Youngstown Posts: 165	Alright I have the problem almost solved. I just did the old soap and water thing because I couldn't find the brake cleaner. And it was the throttle body gaskets. I just re-assembled it with silicone gasket maker and that stopped it, but I only did one side of the throttle body spacer. Most of the whistle is gone, and I know the problem. I got to take it out for a ride tonight too, and it definitely has more off the line and, well, everywhere. The only thing I noticed was a little softness for the 1st 1/4 inch or so of gas pedal, even though the throttle body does open all the way. And I think I saw something about using a hose somewhere around the pedal to get rid of that feeling. If anyone else knows, let me know. I'm going to try and get some pics up tomorrow. Thanks for the help. Oh and one other fairly significant difference...the exhaust. It definitely is deeper and quite a bit louder at wot. Last edited by 9986paulk : October 27th, 2009 at 08:13 PM.

October 30th, 2009, 11:00 PM	#15
Ticket-Me-Yellow Hardcore Enthusiast 2001 Mustang V6 14.89@93 mph Join Date: Nov 2006 Location: Hawthorn Woods, IL Posts: 1,006	Hey ive seen that before! Looks very nice! __________________ M112 Kit Complete Waiting for Water/Meth injection kit and Tune

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October 26th, 2009, 10:34 PM	#3
9986paulk Regular 1999 Mustang V6 Join Date: Dec 2008 Location: Youngstown Posts: 165	Well, OK I got everything installed and ready to go. I cut a pipe and used some rubber connectors to make the intake pipe still go into the fenderwell(though it doesn't look very nice with 2 different colored connectors and pipes, but it does eliminate one 90 degree bend). But when i start it I have this very high pitched whining noise, that I'm positive is a vacuum leak around the throttle body or the IAC port underneath where it goes into the manifold. If anyone else has had the problem please help. We took off the belt to make sure it wasn't any accessory, and it wasn't. And still if anybody knows how I can turn off the EGR with my X-Cal 3, let me know. I have the tune for the manual transmission, but didn't swap it out yet so I'm stuck with the auto and I don't want to pay $59 for something that I'm only going to need for a little while. Thanks again everyone.

October 27th, 2009, 08:26 AM	#5
9986paulk Regular 1999 Mustang V6 Join Date: Dec 2008 Location: Youngstown Posts: 165	yea i have the iac shaved, it's a kit from VAP.

October 27th, 2009, 08:48 PM	#9
9986paulk Regular 1999 Mustang V6 Join Date: Dec 2008 Location: Youngstown Posts: 165	Thanks, that's exactly what I was looking for.

October 27th, 2009, 09:07 PM	#10
9986paulk Regular 1999 Mustang V6 Join Date: Dec 2008 Location: Youngstown Posts: 165	And another good thing...which really wouldn't be much of a problem anyway, is that its not throwing any codes for the EGR being gone. Not yet at least. Where can I get the block off plug for the headers? Until I get it, I'm just going to heat up whats left of the pipe with a torch and squeeze it together to stop the exhaust leak sound and all that crap from blowing around in the engine bay.

October 29th, 2009, 04:50 PM	#12
9986paulk Regular 1999 Mustang V6 Join Date: Dec 2008 Location: Youngstown Posts: 165	So does anyone know on that? The size of the plug/bolt?

October 29th, 2009, 06:57 PM	#13
9986paulk Regular 1999 Mustang V6 Join Date: Dec 2008 Location: Youngstown Posts: 165	Oh and I figured out why the pedal was "squishy". It didn't have to do with adjusting the pedal, it was the throttle body. Right where the extension arm joined the throttle body shaft, it wiggles a little less than a half an inch, which it moves when the pedal is pressed before there is a throttle response. Other than that, seems good.

October 30th, 2009, 10:54 PM	#14
9986paulk Regular 1999 Mustang V6 Join Date: Dec 2008 Location: Youngstown Posts: 165	Here's a pic of it installed. its not the best quality, but it'll do. I like how it looks and sounds way better. It even somehow made my cold start problem a little better, not sure why on that.

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