Changing my intake manifold gaskets on my o3 4.6 have a few questions

[03 Limited 4.6]

Ok heres what happened. Well i changed my thermostat yesterday in my explorer because when i go out in the morning to start it to let it warm up say 15 minutes come out and the heat is still blowing cold until i start driving down the road for a while. Well after the new thermostat i have hot heat but now since it closing and opening and building pressure my intake is leaking where the aluminum crossover meets the plastic and the main intake gaskets failed. Is there a gasket that is replacable where the crossover meets the plastic or will i have to replace the intake manifold? Also i just got the intake off and when started pulling it out some plastic was just breaking off in my hand i stopped halfway pulling it out and looked on the side and said holly crap this mug is broken haha but once i got it out it was a sleeve over the bottom of the intake which is very brittle and falling apart. So do i have to reuse this or can i put the intake back on with out it. I am assuming it is there for a reason being it has a foam surrounding. Also is the mustang intake the same on our explorers and i should know the answer to this but i dont. Does one have shorter/longer runners then the other. And has anyone put the typhoon manifold on our trucks and if you have what did you have to do to make it work? Thanks,Joe

 

[anaab]

Did you ever find out what this foam enclosure is or what it does? I'm in the middle of replacing the intake on my '04 4.6L and found the same part in the same condition (crumbling).
When I tried to ask the parts guy at the dealer he looked at me like I was nuts (OK so maybe he knows me already).
Have to wait until the new intake arrives tomorrow to see if it's included and I don't want to wait another week to order that enclosure.

 

[anaab]

Installed the new intake last night. The replacement (OEM) came with the enclosure.
Still don't know what it does but it's on there now.

 

[pet575]

Mine needs replacing. Did you pay $400 for the Ford part or were you able to locate an OEM at an aftermarket parts store for a more affordable price?

Is this part the entire intake or just the coolant intake? Parts guy at my Ford stealership couldn't answer that question for me.

 

[matt0248]

Dorman makes a replacement part for about 1/2 the dealership price. Even comes with a new Thermostat.

 

[JoshMcMadMac]

Mine needs replacing. Did you pay $400 for the Ford part or were you able to locate an OEM at an aftermarket parts store for a more affordable price?

Is this part the entire intake or just the coolant intake? Parts guy at my Ford stealership couldn't answer that question for me.

Dorman 615-175, about $160:
http://www.amazon.com/Dorman-615-175-Intake-Manifold/dp/B000CIXMIC

It has a couple spacers and things along with it to work between different versions of the 4.6L. As I recall the directions suggested that I needed to use some of them that I did not, like the EGR spacer, so just watch what they are for and use good judgement if they are needed. Also be careful of the EGR tube. It is in the way of the intake manifold coming straight out, and if care is not taken you can break that tube. That is a repair that really, really sucks to do...ask me how I know. :thumbdwn:

 

[pet575]

Thanks guys. Ordered it and it arrived yesterday. Before I tear into this project (might make a nice post with pics) are there any difficult parts to remove or tricky issues I should be aware of? I've read some Mustang and Crown Vic posts indicating trouble with brackets, having to remove the windshield wiper motor, difficulties with the throttle body, etc. so I'm just wondering if our Explorers have similar issues.

Any extra parts, gaskets, etc. that I will need? EGR valve gasket? Going to change the rest of my spark plugs while I'm doing this job. Forgive me if my question about parts/gaskets is dumb; I have not yet opened the box for this intake.

 

[JoshMcMadMac]

Thanks guys. Ordered it and it arrived yesterday. Before I tear into this project (might make a nice post with pics) are there any difficult parts to remove or tricky issues I should be aware of? I've read some Mustang and Crown Vic posts indicating trouble with brackets, having to remove the windshield wiper motor, difficulties with the throttle body, etc. so I'm just wondering if our Explorers have similar issues.

Any extra parts, gaskets, etc. that I will need? EGR valve gasket? Going to change the rest of my spark plugs while I'm doing this job. Forgive me if my question about parts/gaskets is dumb; I have not yet opened the box for this intake.

You should be good with everything that came with the intake, although it helps to have some RTV on hand just in case, as well as the yellow "Super High Tack" gasket adhesive...it really helps with holding a gasket in place as you are putting things back together. Also heed the advice from my previous post on the EGR tube, as I will reiterate the intense level of suckage that was that replacement.

 

[pet575]

So when you say to take care not to break the EGR tube, what exactly do you mean? Don't touch it? Don't move it more than 1/8" in any direction? Don't try to bend it at all? What did you do that caused you to break it?

 

[esclamada]

The EGR tube somehow goes from the back (firewall) to the driver side of the manifold. You have to slide out the manifold when taking it out.

I have to tackle this same project next month, I got the Dorman replacement for weeks now waiting to be installed. Weekends have been very busy for me this summer.



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[pet575]

I've got this thing to a point that I believe I am close. Only problem is that I need to remove the fuel rail and I don't know how to do that. Can anyone help me with that?

I'll try to get some pics posted quickly.

 

[pet575]

Here is a pic of one of the four connectors from the fuel rail to the injectors. How do I disconnect without braking this.

I've read somewhere that these injectors just pull out. Is that true? Would I just be better off pulling the rail and all the injectors out as one piece, disconnecting the fuel supply line to the fuel rail instead? If so, do I need a special tool to do that?

 

[JW]

You can remove the rails and injectors, but you should spend the ten bucks on the quick disconnect kit Autozone has and disconnect the fuel line from the driver's side rail instead (after relieving the pressure, of course).

 

[JoshMcMadMac]

The injectors just seat in the intake with o-rings. Yank them out, and make sure the o-ring comes with them. It is easier to use the disconnect tool on the fuel rail and then remove the injectors, but you can do it without removing it if you want to.

 

[pet575]

Suggestions on best way to relieve fuel pressure now that I have this thing half apart? Is pulling fuse for the fuel pump enough since it has been sitting now for about 20 hours?

 

[JoshMcMadMac]

Suggestions on best way to relieve fuel pressure now that I have this thing half apart? Is pulling fuse for the fuel pump enough since it has been sitting now for about 20 hours?

There should be a shrader valve on the fuel rail you can depress. Otherwise, just be careful and be ready to catch any fuel that comes out.

 

[JW]

Yep. All the methods will result in a little residual fuel spillage. I pull relay #48 with the engine running. That relieves pressure but doesn't clear the rails completely.

 

[pet575]

Thanks for all the help talking me through this, guys. I had already torn the engine apart a bit so I couldn't run it to relieve the fuel pressure. I pulled the fuses and relay and it had also been sitting for 20 + hours. I disconnected the quick connect fuel line connection and less than a thimble full of fuel came out of it so that made it pretty easy.

Got the replacement done and the old intake was cracked and falling apart in several places. It was unbelievable what kind of shape it was in. I got some photos and am going to start a thread to put them in.

I had replaced COPs on the #5 and #8 cylinders previously. #6 and #7 didn't look great either. After reassembly and driving, I'm having some hesitation/stumbling/slight jerking/slight power loss when in overdrive at 45MPH+. Engine started throwing a code on my way to work this morning. I'm expecting to see a cylinder misfire code in one or more of the cylinders 5-8. There was more fluid in #5 and #8, like there was when I first changed those COPs, so it won't surprise me if I have an issue there again.

 

[pet575]

Here's my thread I created:

How to change intake on 4.6L V8

 

[wesalexleft]

Dorman Intake Manifolds 615-175

Looking at the Amazon link above for my 2003 Monty 4.6L, but according to Amazon, this part does not fit? Am I good with the Dorman 615-175 or is the mercury different for some reason?