Ford Repair: P0104 P0107 on 2000 windstar SE 3.8L, oil contamination, smoke test


Question
134,000 miles on the van...

O.k....June of '06 I got the P0104 & P0107 codes and ended up replacing the intake gasket set, vaccum line, & PCV valve...I was told the gasket set went bad because of oil contamination that was getting in due to the valve cover design...Ford said there was a updated valve cover, which I did not have put on. I just told them to replace gasket set, pcv valve, vaccum line, and clean oil contamination...the check engine light went off following the above repairs...

this past week, over a year later...I got the same two codes...had midas do a diagnostic test...they said they also did a "smoke test" on the upper intake and lower intake and saw a leak in the lower intake right where a small rod runs through the intake due to the seal around the rod...

They believe they need to replace the lower manifold which has been updated by ford...they said they would also want to do the upper intake just to be safe...& the gasket set would have to be replaced again...but said they thought it had nothing to do with the valve cover design...

do you think its just another oil re-contamination to the gasket set because I never replaced the valve cover in June '06...or is it this whole new problem, with just the same codes, like they seem to think...

I'm just unsure because I've never heard of this "smoke test" thing...

I appreciate any help you can give me...I see that there is a retired ford expert on vacation...any chance he can shed some light on this

Thanks,

Answer
I have never understood plastic parts on an engine.Call me old fashioned that way.I wouldn't kick myself in the foot too hard.I am sure you were doing what was economically feasible to you.However,you should have replaced the valve cover.I am surprised it went that far.