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Ford 4.6L V8 Intake Manifold Replacement
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- เผยแพร่เมื่อ 8 เม.ย. 2014
- Complete instructions for intake manifold swap on 4.6l Ford V8 engine. It is easy! I got new Dorman 615-175 to replace stock OEM part. Each step was relatively easy but there were a lot of steps. Took me 6 hours total for removal and repair. The Dorman part came with new thermostat and O-ring. Also had new alternator bracket as old one could not be used. This part is improved over original OE as has O-rings for all ports so a gasket is not needed. No more leaking coolant. Fits 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009 and 2010 Crown Victoria and other Ford, Lincoln, Mercury V8 motors such as Mustang, Explorer, Expedition, Grand Marquis, Town Car. The 5.4l truck and Expedition should be similar.
I'm going to do this job tomorrow, everyone wish me luck.
Thanks for the video.
How did it go?
@@s0lidpikmin oh well your there might as well replace spark plugs and wires too!
@@thegamermechanic2970 UPDATE: Mr Ahmed is still in the process of removing the intake manifold
Abdiassis Ahmed same here on a 03 towncar , I found one at Walmart app for $118 and its a doorman also , what do you think
@@edward1967able I might look into that same one for my 97 Marquis
THANK YOU!! This gave me the courage to change the intake on my 2011 Crown Vic today. Took me 3 hours flat - shade tree mechanic, taking it easy, hand tools only, no air. Your video was so helpful, thanks!!
Three hours is a great time. Think I took near 5 but was not rushing.
@@KentDiego dear i have 2012 and start leakage so in saudi arabic they make cold welding did this work i will used balazona welding
@@enriquegilmour The GM should not be any harder. It just takes time and patience. Buy a manifold from Ford Racing to get best price for factory part.
I'll venture to say that you maintaining your composure throughout as you clearly did will have resulted in more people attempting this, and succeeding, than otherwise would. (I, who would ordinarily never consider such an operation, have gone so far as to price a manifold... I have even thought it might be a pleasant task if I had a friend of your bearing standing by during the process. I know this much: I sure would like to have a successful operation like this behind me, to brag about!) Thank you.
Thank you so much for making this video! Me and a friend of mine had to take apart his Grand Marquis' intake manifold in order to fix a really serious leak. The job was way bigger than anything we've done before and without this video there is no way we would have gotten it apart and back together again. You did a fantastic job of showing every important part of the job, and had a lot of helpful tips too! Thank you!
Kent, thanks for the vid. Just learned that this needs to be done to my wife's car, and this shows me that it's no harder to do than the last time I did one, about 1980, on an Olds. The only things I would suggest to you, in this age of phones that are smarter than I am, is to take step-by-step photos, and to buy a bunch of muffin tins. You can use them to hold your hardware, label them with a china marker or grease pencil, so that you put the right bolts on the right holes, and be more secure that you haven't lost any parts. Then you can use them to make corn muffins...I m'self also prefer to label all hoses and electrical connections, but that's just my lack of confidence...Appreciate your posting this!!
Of course, it's December in Chicago...Anybody have a heated garage I could borrow for a day? I'll bring all my own tools, even the 8mm allen wrench...
Great video Kent! I discovered a leak recently while changing out valve cover gaskets on a 2000 Ford Mustang GT. The introduction is also the only place I could find on the Internet that clearly pictures the o-rings seated onto the manifold and explains the removal of the old gasket and prep. Thank you for sharing!
Excellent video. Used it as a guide to help me change out the intake manifold on my 2003 Grand Marquis. I also changed the plugs and coil packs at the same time. I wish I had replaced the injector o rings as well but I am not having any issues without doing them. I did not put the old heat/sound shield on the bottom of the new manifold since it was crumbling away as soon as I touched it. I read several other forums where all the responses were to disregard trying to find one to replace it. Thanks for posting!
Sir, You are very good teaching people what to do on something like changing the maniflod. thats a big job and you make it look easy.
this video really helped a lot and saved me a lot of money I found the manifold on Amazon for 300 bucks the local auto shop was trying to charge me 12 to 1400 for parts and labor took me a few days to get that bracket due to the weather conditions however I did not reinstall the bracket after replacing the manifold there was also another bracket wiring harness in front of that bracket I ran into during disassemble of the manifold bracket
Congrats on a job well done, Sir! I want to add a few things for anyone attempting this procedure. If you are going to disconnect the fuel line, start your car and then give your inertia switch(usually in the trunk) a smack with a screwdriver handle which will cut off the fuel supply and the engine will run out the fuel and then stall. Just make sure to reset the inertia switch button when you're done or the car won't get any fuel to the rails.
You didn't mention draining the coolant below the level of the thermostat before removing it. If you don't, you and your engine will be wearing coolant.
Good tip when purchasing a new intake: make sure the mounting holes have the brass inserts so you can use the original screws. Those self-tapping screws into the ABS plastic is a hideous idea! You know that ain't gonna last long!
One last thing. When removing any hardware(screws, nuts, washers) either try to see if you can keep them installed into the component you're removing or at least bag-n-tag them. Leaving them out on a surface can get bad real quick. Imagine the dog or your kids come running through and bump the table they're on and everything goes flying and what you can find is all mixed up! I'd hate to have my project on hold while I have to hunt for hardware at the auto parts store or online or at Pick-N-Pull, of all things!
This was a very well done video and I was able to complete this job during this past weekend. I had viewed some other videos that did not have enough detail and very vague. After watching yours, I felt confident enough to tackle this job. It probably took me 8 hours total as I was careful doing each step and a few minor problems along the way. A few things were different on my model. Thanks again and this was great way to save about $800-$900 !
Did this a few months ago to my 98 CV. Damn bastard bracket almost put the quit in me. Not at all ashamed to say I cried a little and raged a lot.
Hahaha...thanks for that!
I feel you Marcel
Swivel 3/8s and a shallow 15mm. Takes 3 seconds w electric ratchet
No wonder the garages charge so much for labor lol
I did too. Don’t feel bad, I had to step away for a day to think clearly
great video thanks for saving me so much money man. 210,645 views... each person watches about 20 times. so about 10,000 people watching. about 200 bus saved per person......you just saved the world about 2 million dollars....thanks man
Or 8k of the 10k watched it, got over ambitious and took on a job they couldn't do costing them more in the long run haha
sir you are a Superman I have always been mad at myself for paying the mechanics to do that but after seeing you do it I know that there is no way I could do it great job well done
Great instructional video. Followed it step by step, pausing the video as I worked on my 04 Mercury. Everything was spot on. Never changed an intake before, but this video made it a breeze. Thanks much!
How long did it take you?
Thank you for taking the time to do this video!
You did an AWESOME JOB!
Now I am not afraid to save myself the $900.00 bucks the mechanic wanted for this job.
You are the MAN!
7 years later and shops want 2500.....🫣
Digging around it looks like I am about to have to do this. Thanks for doing such a thorough video. For the life of me I can't figure out why someone would come check out this video only to be a dick and comment about the parts quality or how they did it better. This video is the difference between me paying $700 for someone else to do it or doing it myself for < $300. Thanks!
sheep4269 Except dorman manifolds are shit though
AKS the one he had on there was not shit it had the aluminum crossover for coolant. The all plastic models suck and fail. His got fucked up not failure there is a difference. Also Dormans suck look at the plenum the runners feed into on the new dorman intake very small the oem is much bigger it makes a difference in performance. If your seeing failures of the aluminum cross over design at 100K its because some one don't know how to use a torque wrench. My all plastic pos intake didn't fail untill 165K
Did this job the other day. Everything went as planned. I used all OEM parts as replacements. I also used very light coating of rtv gasket materials around all ports mainly due to some pitting in the head near cool ports. My whole body hurt for a week 😂
Started watching this because I had to do the gaskets on my 04 4.6l explorer. Helped me greatly! I found that i had an internal piece of one of the coolant passages broken on my 20 year old stock manifold so I'm about to put in the same Doorman manifold! Thanks for the guidance.
Kent. I know this video is old but I wanted to say thanks. Your video helped me a lot. I did this job today and I couldn’t be happier with the results. Thanks!
How long did it take you?
Awesome video, changed this out in about 3 hours now I'm just waiting for my part to get here
Very old video, but you mentioned that long bracket/manifold bolt and remembering that saved me ALOT of time.
Glad I found this, i have a 98 vic, and my intake manifold cracked, thanks for the video
Hi kent. I used your video and it worked great. To get at the bolt in back i took off the wiper assembly. Made that part so much easier. Thanks.
Kent! Great video man! I have done this countless times, was a ford tech for 6 yrs, I have put this same intake on a 2002 4.6 vic last year, might be doing it again on a 1999 soon. great video for me to reveiw on! Perfect video for any do it yourselfer asweell! thanks for shareing!
K surf why is there coolant on my sparkplugs and coils
@@humbertobuenrostro2053 ur intake is leaking from cracked plastic!! Like mine!!
@@scottyjones27mines too! It's that time of year!
Do you have any idea what the man hours were when you replaced one in the past?
@@timothyfrost8807 as far as flat rate hours just off expeiriance shooting from the hip 2.5 to 3.0 hours is fair. There are some issues that can come up. always make sure you have no coolant in the cylinders after. you want all the spark tubes dry.
The ole razor blade trick. Thanks so much for posting this. Couldn’t of done this without this video!
lol, at the end of the video you said "looks like i'm going to work tomorrow", glad it went well for you. I appreciate this video it reinforces my decision to have a mechanic do this job even though i have a buddy who swears he can do it and only wants a bottle of booze for compensation.
thanks for the video ,
am in the process of swapping out a 5.0 out from my GT and slapping in a 4.6L 3v .. i have everything am just trying to soke up as much info as i can ..
Thanks for the bracket removal tip ive been trying to find a video on this for 4 months since im trying to chang my fuel injectors
I used your video to replace my intake with an Autotecnica FD1413042 intake that uses all the OEM bolts. With your video, It would have take a few hours if it were not for the driver side bracket and second wiring holder bracket that bolts onto the extended stud on the bracket bolt. A swivel 15mm wrench or a low profile socket with swivel ratchet makes. BTW, your video is used as a example on the website.
This video helped me get the job done. Thanks for the help!
Best. Video. Ever. Thank you so much. Fantastic commentary/direction.
great video! I hope it solves my problem! leaking coolant drains from above the oil drain valve area..
Thank you for posting brotha! Just finished putting a new intake my 2005 CVPI and watching this helped me through. But yeah all that work for a plastic nipple haha hopefully never again.
MGMStealthv2 I have a 05 Vic to. I am worried my coolant leaking from the intake is leaking internally now. I am going to replace the intake next week. I been checking the oil and its clean but my oil cap is getting milky. Only has 84k on the car and the intake is fucking me
@@IMP429 after u drive a few mins that milky oil cap will clear out , my 02 4.6 has 350000.0miles on it I hav seen that on my oil lid just after start up but on after few mins driving it's gone??
awesome video very in depth and to the point keep up the good work and keep the vic running
This video made the job easy on my 04 cvpi and the car runs great now!
At 5:30 , on my gf's 01 mustang, that little hose WOULD NOT come off for anything. It had no clips and it spun freely around the metal fitting but I couldn't pull it off, even after all the fuel pressure was relieved. I didn't want to pry it off and damage it so I just kept them connected and set the rails off to the side without the injectors. Thanks for posting this video! Although for some reason the 4.6 I'm working on is a little backwards, the air intake is on the passenger side and the battery is on the driver side.
Wow you're lucky! My heater hose nipple just crumbled and its -16 degrees outside.
I had to scrape inside of my windows. Didn't have much power the last few blocks home.
Is that the nipple on passenger side near fire wall
Hey, Kent! It's me again. I wanted to make a couple of points about the Dormann manifold, but first:
Your instructions and tips were SPOT ON!!! Thank you sooooooooooo much for putting this video up here!
I did lose some gas mileage, but otherwise the manifold is functioning normally. No leaks of any kind.
I'll let you know if there are any new developments in my case, but I've had the manifold on for a while now and so far, so good!
Thanks again!!!!!
John Baird I want to know how to remove the rear axle on a 99 Mercury grand marquis to replace the axle bearing and seal.
John Baird
good work, and your pleasant throughout as well.
Ok wanted to ride around a little bit to make certain that the problem was fixed. I think I figured it out, as I said my thermostat would go up high and drop back down to normal and my car would hesitate. I changed out the intake manifold and the problem still persists. I even change my ERG valve, but to no avail.
So I took it to the Mercury dealer and they pulled up two misfire codes. Then they proceeded to tell me that to fix this problem it would run me $2500!! On top of that they couldnt tell me Definity what was leading to the miss firing of my vehicle.
I was just on the verge of selling it when I decided to change out my spark plugs and coil packs. Lo and behold upon changing my spark plugs I noticed that I had burned antifreeze all down in the spark plug bay. You can see where antifreeze had gotten down into the spark plug base and had burnt off around the spark plugs. Not to mention that all of my coil packs appear to be worn. After changing this my car rides like a beast!!
So to anyone who changes there intake manifold which is composite I would advise to change out your spark plugs and coil packs on this make and model of vehicle. Ford, Lincoln, mercury.
B. New I have had two coil packs go bad so far. Very expensive for one at local parts store. You can get all 8 on Amazon for $50.
How did you suck coolant out of the spark plug wells?
@@user-xg8yy7yl1d use the spray nozzle from a spray bottle. make sure it has a long straw.
@@getupryan That's brilliant, thanks!
I do like the way that you laid out the bolts and components!
Was just told today that my manifold needs to be changed. Had problems with the ignition coils in the past (3 of them). Going to talk to my neighbor (a mechanic) and see if he can help me do this. Thanks for the video! Great info, and hoping I can do it for way less money!
I had two coils go bad too. Might be a good Idea to replace all 8.
Yep, that's the plan, plus the water pump and serpentine belt, all in one shot!
excellent video, you are a top notch mechanic, narrator and videographer.
I just did this. You had the best video and it was the easiest way for me too. Thanks for taking the time to upload this Kent!!
Glad it helped
Thank you for the video, very nice easy to follow. You made my job here very easy.
Thanks For The Video Imma Get Started Now Damn Plastic Bullshit Mine Cracked At The Thermostat Area
Thank you for the video, i changed mine and i followed everything you did. Now it runs great! I think i need to change my air actuator, I think i might be why mine busted. Any ways thanks again and good luck to you in the future :)
I successfully did mine using this video. Thanks! One suggestion though, while you have everything open go ahead and change your spark plugs. I change my plugs a few months later and had one plug give me problems....it did not want to come out so I left it in there. I will attempt to get it out after going to TH-cam university....lol. If anyone have a good TH-cam to watch on this please let me know. Thanks fellow TH-camrs.
Hey Kent ! I really appreciate the detail you put into this video :) THANK YOU. I'm not a mechanic but slowly from various TH-cam videos like these I'm starting to feel like one haha. I wouldn't have been able to this repair without your help ! saved me at least $1000 and got my 2003 Crown Vic P71 back in action ! Keep up the good work man !
*I replaced the Manifold on my 97 Thunderbird with a Dorman 615-178 and it went from running like a piece of Crap to running better than new.*
I put a pi intank on my 96 Cougar best thing I ever did it's a Ford brand by the way
I broke that heater hose place changing that back spark plug lol. Going on a year and a half now and my home depot fix has held up.
Thank you for the responses, sir! I will let you know what happens!
One of the best videos i seen on the intake manifold replacement, thank you!
Glad it helped
Great video! I just replaced mine on my 97 GT! Subscribed!
Thanks for this Video, My 03 Crown Vic Interceptor has the infamous t-stat crossover coolant leak. I'm gonna try the Dorman intake, cause the original ford part is too expensive. .... Thanks again Sir !
Thank you for making the video, this helps a lot!
Great video! Great patience. Thanks this video was very helpful.
The thingamajiggy is the fuel pressure regulator bud, extended studs are used as an earthing source. On different vehicle configurations depending on the country. Left vs right hand drive.
I think mine is leaking in several spots on my 00 mustang gt. It already had the pi intake swapped when I bought it in 2010. Leaking around a few COP holes and just yesterday I saw a huge coolant puddle on the ground above the firewall. Cant see up in there from underneath or on top so gonna finally pull it. American Muscle has them for $249.
Want to do this on my 02 mustang gt. Nipple broke as well when I was pulling out the ignition coil. 😬
Good video. I would have changed that knock sensor out while you had the intake off. The knock sensor on my 4.6 failed at 80k.
A lot of tips, thank you buddy!
Nice job, I just wouldn't tackle this myself, I do brakes etc but this looks like alot of taking sht off lol and hoping nothing gets lost
I got scared when i heard about this issue but i dont think it would be too expensive to have a good mechanic do. I will have this done to my 97 town car before i hit 100k to be safe
Kent, you're awesome! Thanks a lot pal!
Just did mine vehical too and I couldnt find that small lil plastic block position either on a 99 Mercury Grand Marquis or what fit into the 2nd hole the 8in allen key is used for. I used both of the metal screwsin pieces and plugged both holes for now and mine is running great.
Thank you for what you've done I have to replace this part and after the operation I have got a problem I do not know how to fix the engine is running, but when you press the gas pedal the engine is not going quickly and gets the delay in the response I did not find a solution to this problem
So it is a hesitation or stumble off idle? This is symptom of a vacuum leak. Check three places.
1. Hoses at throttle body.
2. EGR valve.
3. The intake mating O-rings at cylinder head (most likely).
Scan the diagnostic bus for codes.
3 words best video ever!!!
Best tutorial video of all time. Thank you very much
Glad it was helpful!
Thank you for making this video, it is greatly appreciated.
Just replaced my Intake yesterday 3-23-15 it went smoothly due to watching your video and knowing what to look out for. Again it was greatly appreciated. - Robert
Is it the same for 2007 Lincoln town car
about to drive mine off a cliff
😂 I have a 2006 F150 5.4 with a cylinder header sensor code. Watching this makes me lose all hope of doing it myself lol.
can I strap mine to the back of your before you do ?? ;-) ;-(
problem after problem with my 2006 Mustang GT ARGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGHHHHHHHHHHHHHHHHH!!!!!!!!!
Great video but my Lincoln had the bracket behind the bracket. They are 13mm and there are two of them. The second bolt is on the engine block and hard to access . Have to make sure the wiring harnesses are unclipped and then use a ratcheting wrench. Had to use leverage . Once loosened it came off by finger. Other than that it went smoothly.
What year is your town car?
@@arizonageorge6164 2001
I'm glad I sold my 2001 f150. The intake manifold was leaking coolant,after I had the metal pipe replaced from a previous leak. Horn went out,blinkers stopped working,a.c. went out too.
Great Job on the video. Way more upbeat than I am about working on cars. Lol
Thanks for sharing Kent.
Good video. Mine just started leaking . Another project. Thanks
Thanks Kent very nice video.I watched your video to make sure I have all parts and tools before I do the change out here in a few weeks.So I had a question about the rubber silicone where you talking about applying it to the gasket's on the manifold ?It will void your warranty.
I believe the ford modular engines are all metric, thank you for the video
You are correct. All mounting hardware on American cars that I have worked on are all metric since about 1985. If you look at a decimal size chart you will see that there are a few sae sizes and metric sizes that are close but most are not.
You may be able to fit a standard sae size wrench on a metric bolt and if it is not too tight that combination might actually work, but if the bolt is very tight where you have to put a lot of pressure on it the standard sae wrench will slip. When i started working on cars all hardware was standard sae and I bought a lot of standard size wrenches. Then metric came along. So now I have two sets of tools, one is metric and one is standard sae.
My 04 Grand marquis thermostat started leaking coolant when reved on the gas.. bad o-ring.. now its dripping coolant behind the thermostat housing. I believe i have a cracked intake manifold thats leads to leakage under the car/firewall.
Just finished mine using your video and another. The other was take off all the things, but helpful. Yours is more practical for the garage rat. Things that took some extra thought: Gaskets on the new intake are the same shape, but different design than what i took off. There are spacers for the alternator bracket to raise it up and compensate for the loss of the added height of the gaskets i took off. Other than that it went as hoped.
Do you mind posting the link to the other video that helped you? Thx!
@@AdamMayor 7 months out is beyond my memory for a video.
@MysticSpank what about loss of height for the egr? Just kind of thinking if the stock gasket raised the manifold up. Then wouldn't when you bolt the egr in it, it would pull the manifold up?
@@Neptune5.56 I had zero issues connecting the EGR. I see i posted a year ago. car is still doing well without any additional work to the intake or EGR.
my broke just yesterday, i was going about 70 and the coolant intake broke off and shot coolant everywhere im not exactly sure what to replace, could someone give some advice it's a 2001 crown victoria
Thanks for the excellent video Kent! You showed great patience with this too.. Since this was 10 years ago anyone found a decent aftermarket brand now that we don't have the Ford oem option? I know this is Dorman here. Have they improved any? (96 Mustang GT npi) Not looking to do the PI upgrade yet.
it was my first time but I did it and it worked out for me and saved me some money thx
I did this job on my 4.6 engine (fordf150); I think there might be two torque sequences that have the same number. I think I messed up and only did the first one. one is inch pounds and the other is ft pounds. Also the egr valve ended up being a problem child. only after I towed the truck to a mechanic did I find out about the egr valve. He couldn't figure it and told me to wait for the truck to throw a code. it did and I had to have a custom exhaust guy do the egr valve.A Month later the cylinder filled with fluid again and I said screw it and bought a new jasper engine. Not a bad job, just take your time.
Great video !!!
I guess I'm going to work tomorrow, lmao!!!
My turn. I'll be starting the process this Thursday night
WHAT is the screw on the right side of the engine under the manifold? It has a wire cuoppling/clip and goes into where the pistons are I believe... Mine is needing replacement
For the record if people are not able to do this, book time is about 3 hours plus parts. I was going to do this month's ago but didn't have the opportunity. Now it's gotten worse and I'm having mechanics at my job do it. Least I get a discount
I also waited. Started around thermostat, then one day, started pouring from that heater hose nipple.
thanks for the vid ,, question: did you notice by taking everything off except the intake,, did it look possible to get to the 2 top transmission bolts? you prob didn't notice it but thought Id ask,, thanks
#1 carwash for engine compartment #2blow it out with air #3no dirt and dust to drop in open valves!
Great video, thank you for posting it :)
same heater nipple broke on mine, home depot got pvc adapter 1/2" to 3/8" JB weld right onto and over that port, good to go, less tgan $6 total and 6hour cure time.
I was thinking of drilling and tapping threads for a brass nipple. In any case there is always an increased risk of having the repair fail when you are in the middle of nowhere.
thanks for video it was reslly helpful
How much for the labor only for this kind of work if I take it to a mechanic? Great video thanks
I think its a temp sensor, like maybe for coolant? But the one on top of the manifold is as well, are there 2 sensors or something?
Just a note! I'm doing this on a 2000 Town Car, and that pain in the ass bracket on the back of the manifold with the two 15mm bolts has ANOTHER bracket on top of it with two 13mm bolts on the back side. That's what the studded portion on the 15mm bolt is for, a 13mm nut goes on that, and then a 13mm a little further toward the passenger side under a wiring harness. Super pain in the ass.
great video and I'm going to do the repair myself, after watching your video and reading a lot of the comments, I'm going to buy the Ford racing intake but, there is a problem using the Ford Intake and that problem is with the alternator bracked. The Ford intake does not come with the new alternator bracket so, my question is....when you were doing your car, could the original alternator bracket have been modified to work with the new manifold? Any help is appreciated.
+daredevil7442 The Ford Racing is the factory original size so the original bracket will work fine. If you try to use original bracket on Doorman it hits the manifold. I show in my video. You could take a grinder and modify original bracket to fit the Doorman. No need to worry about the Ford Racing part, it will fit.
thank you for this video really help Alot
I just bought a new intake manifold and I'm going to do it
GREAT instruction