There are 2 ports on the upper intake manifold, can any one tell me where these are supposed to go? the vehicle i am working on is a friends 98 malibu, and these ports had no hoses connected to them.

Intake torque specs ' FordForumsOnline.com

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May 7, 2010 - 2 posts - ‎2 authors
ISO torque specs for the intake & plenum for a 98 Windstar...3.8 with the ... Our community is here to help you with any questions you have related to your Ford. ... Lower Intake Manifold to Cylinder Head Bolt 8-12 - (71-106).

Torque Specifications - AutoZone

www.autozone.com/.../Ford-Windstar.../Specifications/Torque-...

AutoZoneAutoZone Repair Guide for your 2004 Ford Truck Ranger 2WD 2.3L MFI DOHC 4cyl Engine Mechanical Specifications Torque Specifications. ... Ford Windstar 1999-2003 ... Bolts, Main Bearing Bolts, Rod Brearing Bolts, Crankshaft Damper Bolts, Flywheel Bolts, Manifold. Intake, Exhaust ... Vehicle: 2008 Ford F150, 98 Civic.

images for 1995 ford aspire idle test on egr

it connects behind the throttle body/intake manifold, behind there is a port for 2 hoses one of them is for the upper hose on recovery tank

Ha, you tried to fool me with the bit about a 3.5 L motor--I could find that one...here is the complete procedure from AutoZone.com:




Installation To install:

1. Clean the gasket mounting surfaces. Be sure to inspect the manifold for warpage and/or cracks. If necessary, replace it.
2. Position the gaskets on the cylinder head with the port blocking plates to the rear and the This Side Up stamps facing upward. Then apply a 3 / 16 in. (5mm) bead of RTV sealant on the front and rear of the engine block at the block-to-manifold mating surface. Extend the bead 1 / 2 in. (13mm) up each cylinder head to seal and retain the gaskets.
   
   Fig. Lower intake manifold tightening sequence-4.3L engines
   
3. Install the lower intake manifold. Tighten the bolts in sequence and in 3 steps, as follows:
   
   
   
   1. Step 1: 26 inch lbs. (3 Nm).
   2. Step 2: 106 inch lbs. (12 Nm).
   3. Step 3: 133 inch. lbs. (15 Nm).
   
   
4. Install or connect the following:
   
   Power steering pump Alternator bracket bolt near the thermostat housing Wiring harness to the lower manifold components, including the injector, EGR valve and ECT sensor Air conditioning compressor bracket-to-the lower intake manifold pencil braces
   
5. Install transmission oil dipstick tube, if necessary.
   
   Fuel supply and return lines to the rear of the lower intake
   
6. Temporarily reattach the negative battery cable, then pressurize the fuel system (by cycling the ignition without starting the engine) and check for leaks.
7. Disconnect the negative battery cable.
8. Install or connect the following:
   
   Heater hose to the lower intake Upper radiator hose to the thermostat housing Distributor assembly and engage the wiring Ignition coil Connect vacuum hoses to the upper and lower intake manifold. New upper intake manifold gasket, making sure the green sealing lines are facing upward Upper intake manifold Manifold retainers. Tighten them to 88 inch lbs. (10 Nm) using two passes. Purge solenoid and bracket Brake booster vacuum hose at the upper intake manifold PCV hose to the rear of the upper intake manifold Vacuum hoses to both the front and rear of the manifold assembly Throttle body Throttle linkage to the upper intake Wiring to the upper intake components including the TP sensor, IAC motor, MAP sensor and the fuel meter Engine cover Air intake assembly
   
9. Connect negative battery cable.
10. Refill the engine cooling system.
11. Start the engine and check for leaks.

The fuel pressure regulator is located under the upper intake plenumn. (The black plastic cover that sits on top of the intake manifold)
After removing this upper intake, the regulator will be on the back side of the fuel injector inlet housing.
Good luck

TSB
05-22-6
ISSUE:
Some 2001-2003 F-150, 2004 F-150 Heritage and 2001-2003 E-150/250 vehicles equipped with a 4.2L engine may exhibit the malfunction indicator lamp (MIL) on with diagnostic trouble codes (DTCs) P1131 and/or P1151 (system too lean bank 1 or 2). This condition may be due to leaking isolator bolts/port gaskets in the upper-to-lower intake manifold mounting area. This condition is sometimes intermittent and may not be apparent on a warmed-up engine.


SERVICE PROCEDURE

Perform a self test. If DTC P1131 and/or P1151 are the only codes stored in the powertrain control module (PCM) proceed to Step 2. If any additional DTCs are present, follow normal diagnostic procedures found in the PC/ED Manual.

Remove the upper intake and replace only the port gaskets (9H486) and isolator bolt assemblies (9S479). The new isolator bolt assemblies use a rubber material that is green in color, do not install the old isolator bolt assemblies with the black rubber material. Do not replace any other intake parts or gaskets.
While the upper intake manifold is removed, check the exhaust gas recirculation (EGR) orifices that are pressed into each primary port of the lower intake manifold. If any of the orifices are plugged with soot, clean and unplug them with a pick and solvent.

PART NUMBER PART NAME
1L3Z-9H486-AA Port Gasket
3F2Z-9S479-AA Isolator Bolt

This is the entire task for it. It sounds like you might not have torqued it correctly, or your intake is cracked. But take a look at all of the info:

VIN K Engine On these engines, the upper and lower intake manifolds must be removed separately.

1. Properly relieve the fuel system pressure, as outlined in Section 5 of this manual.
   
2. Disconnect the negative battery cable.
   
3. Drain the cooling system into a suitable container.
   
4. Remove the fuel injector sight shield and air intake duct.
   
5. Tag and disconnect the spark plug wires on the right side of the engine and position aside.
   
6. Remove the manifold vacuum source.
   
7. Remove the fuel rail.
   
8. Remove the EGR heat shield.
   
9. Unfasten the cable bracket-to-cylinder head mounting bolt.
   
10. Disconnect the throttle cable.
    
11. Remove the throttle body support bracket.
    
12. Unfasten the upper intake manifold bolts, then remove the upper manifold.
    

This engine has two bolts which are hidden beneath the upper intake. These bolts are located in the right front and left rear corners of the lower intake manifold. This is why it is necessary to remove the upper before servicing the lower manifold.

1. Disconnect the upper radiator hose.
   
2. Remove the alternator, as outlined in Section 2 of this manual.
   
3. Remove the drive belt tensioner.
   
4. Remove the EGR valve outlet pipe.
   
5. Unfasten the intake manifold bolt, then remove the manifold from the vehicle. Remove and discard the gaskets. Thoroughly clean the gasket mating surfaces, intake manifold bolts and bolt holes.
   

To install:

1. Position a new gasket, then place the lower intake manifold over it. Apply a suitable threadlocking compound to the bolts, then install them. For 1995 vehicles, tighten the bolts twice, to 88 inch lbs. (10 Nm), in the sequence shown in the accompanying figure. For 1996-97 vehicles, tighten the bolts to 11 ft. lbs. (15 Nm), in the sequence shown in the accompanying figure.
   
1. Install the EGR valve outlet pipe.
   
2. Install the drive belt tensioner.
   
3. Install the alternator.
   
4. Connect the upper radiator hose.
   
5. Position the upper intake manifold on the lower manifold. Install the retaining bolts and tighten to 89 inch lbs. (10 Nm).
   
6. Install the throttle body support bracket, then connect the throttle cable.
   
7. Install the cable bracket-to-cylinder head mounting bolt.
   
8. Install the EGR heat shield.
   
9. Install the fuel rail.
   
10. Install the manifold vacuum source.
    
11. Connect the right side spark wires on the right side of the engine.
    
12. Install the fuel injector sight shield and air intake duct.
    
13. Fill the cooling system with the proper type and amount of fluid.
    
14. Connect the negative battery cable. Start the engine and check for leaks. Check the cooling system, and add as necessary.
    

Note, removing the upper intake manifold is not necessary when removing lower intake manifold, they are removed as an assembly.
Disconnect negative battery cable. Drain cooling system. Remove air cleaner assembly and inlet duct. Mark and remove distributor. Remove upper radiator hose at thermostat housing. Disconnect accelerator and cruise control cables. Remove heater hoses from intake manifold. Remove EGR pipe.
Disconnect fuel lines at rear of engine. Remove AC compressor and set aside(leave hoses connected). Remove canister purge solenoid. Disconnect theSCPI injector, ignition coil, Ignition Control Module, generator,IAC motor, TP sensor, O2 sensor, Exhaust Gas Recirculation valve and Engine Coolant Temperature sensor wiring harness connectors. Remove PCV valve and hose. Remove lower intake manifold bolts. Remove lower intake manifold.
Installation.
Always use New O-rings when reconnecting fuel lines at rear of engine. Apply a bead of RTV silicone sealer along the front and rear sealing surfaces of the block.See Fig.6. Install new gaskets and intake manifold on block while RTV is still wet to the touch. Use Threadlock 12345382 or equivalent to lower intake manifold bolts. Tighten lower intake manifold bolts in sequence to specification table. See fig. 7. To complete installation, reverse removal procedure.

3.8L Engine

NOTE The 3.8L (VIN K) non-supercharged engine uses a two-piece intake manifold consisting of an upper air plenum which mounts the throttle body and a lower intake manifold assembly which houses the fuel injectors. The 3.8L (VIN 1) supercharged engine uses a similar lower intake manifold. The supercharger serves as the upper manifold.
Lower Manifold

NOTE Two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake manifold is removed. These bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.
The 3.8L (VIN 1) supercharged engine uses a manifold similar to the 3.8L (VIN K), but the supercharger serves as the upper manifold.

1. Disconnect the negative battery cable.
2. On 3.8L (VIN 1) engines, remove the supercharger assembly. Please see the procedure in this section.
3. Remove the upper intake manifold using the procedure above.
4. Remove the EGR outlet pipe from the intake manifold.
5. Detach the engine coolant temperature sensor wiring harness from the sensor.
6. Remove the lower intake manifold bolts and carefully lift off the manifold.

To install:


Fig. Lower intake manifold bolt torque sequence-3.8L (VIN K) engine

1. Clean all parts well with degreaser, especially the gasket seal surfaces on the upper and lower manifold pieces and between the lower manifold and the cylinder heads..
2. Install new gaskets to the cylinder heads and new seals to the engine block. Carefully lower the manifold into place. Apply thread-locking compound to the bolt threads. Make sure to install the two hidden bolts in the lower intake manifold. Hand start all bolts, then torque evenly to 11 ft. lbs. (15 Nm). Follow the toque sequence, starting in the center, then working outwards in a circle.
3. Install the remaining components in the reverse order of the removal process.

Upper Intake Manifold (Plenum)

1. Disconnect the negative battery cable.
2. On 3.8L (VIN 1) engines, remove the supercharger assembly. Please see the procedure in this section.
3. Tag for identification, then remove the right side spark plug wires.
4. Disconnect the ignition wires from the fuel rail.
5. Remove the fuel rail. Please see Section 5.
6. Remove the cable bracket from the intake manifold.
7. Remove the throttle body.

NOTE Two bolts which fasten the lower intake manifold to the cylinder head are accessible are accessible only after the upper intake manifold is removed. These bolts are located in the right front and left rear corners of the lower intake manifold.

1. Remove the upper intake manifold bolts and carefully lift the upper intake manifold from the engine.

Fig. Upper intake manifold and bolt torque sequence-3.8L (VIN K) engine
To install:

1. Clean all parts well with degreaser, especially the gasket seal surfaces on the upper and lower manifold pieces.
2. Install new gaskets to the cylinder heads and new seals to the engine block. Carefully lower the manifold into place. Make sure to install the two hidden bolts in the lower intake manifold. Hand start all bolts, then torque evenly to 89 inch lbs. (10 Nm). Follow the torque sequence, starting in the center, then working outwards in a circle.
3. Install the remaining components in the reverse order of the removal process.

YOU NEED TO REPLACE THE UPPER INTAKE MANIFOLD. ALSO, YOU WILL NEED TO REPLACE THE LOWER INTAKE MANIFOLD GASKETS. THIS IS A MANUFACTURING FLAW. THE PLASTIC INTAKE CRACKS CAUSING AN INTERNAL COOLANT LEAK. YOU CAN RESEARCH THIS ON LINE.