Oil in the Intake?

2001 Windstar was doing the old stalling job lately. The Air Intake seemed to be making some strange noise. I wanted to make sure that nothing was clogging it so I opened it up. There seemed to be what looked like oil (at first I thought it was mud, but it was oil) pooled in the intake. Where the intake connects to the intake manifold, there was some oil, but not much. On the piece between the intake manifold and filter, there was lots of oil. There was also some in the filter section but not any once you pass the filter and start heading into the fender. It was dry as a bone.

Is this normal (it doesn't seem like it)? It's my girlfriends car, and I am just starting to try to fix it. I read up on all the threads about stalling, helpful info. Thanks for any help.

thats normal, its part of the PCV system, it prevents the crankcase from sludging up.

This is a PCV design issue. Lots of newer fuel injected cars collect *some* oil in their upper intakes, but the 1999+ windstar 3.8 collects so much, it actually pools in there, as you've seen. This pooling over time degrades the rubber-like seals that seal the bolts that hold the plastic mid- intake to the aluminum lower intake (isolator bolts), plus it ruins "O" rings that seal the mid intake to the lower intake (port seals). Ford supposedly "redsigned" the front valve cover with a baffle to minimze oil carry-over. Not sure if it works though. You could get inventive & install a demister can, or large see-thru filter inline on the PCV hose to seperate out oil droplets. I've been spraying intake cleaner thru my PCV line (while van is running) about every other oil change. My thinking is *maybe* this will help flush out any oil in the nooks & crannies. Dunno for sure. Never had the top of the upper intake off. I'm at 41500 miles on my 2001 LX.
G/luck
Joel

Ford supposedly "redsigned" the front valve cover with a baffle to minimze oil carry-over. Not sure if it works though.

The redesigned valve cover came on the 2001 and newer Windstars so I think the poster answered your question since he has a 2001 and is still getting oil.

The redesigned valve cover came on the 2001 and newer Windstars so I think the poster answered your question since he has a 2001 and is still getting oil.

Thanks Lewis. Good info :cheers: !

Joel