How-to
2001 Ford Crown Victoria Intake Manifold Replacement
The original plastic intake manifold on a 2001 Ford Crown Victoria cracked and leaked coolant onto the ignition coils. Benfolio replaced it himself with a Dorman PI replacement that uses an aluminum crossover.
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Step 1
Confirm the failure before starting. Benfolio reports the original plastic intake was blown and soaking the coils with coolant, so the car was left at work. A second photo shows the original plastic intake's casting with a wrench on it; Benfolio says his build date is outside the police recall but within the civilian recall.
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Step 2
Check whether the repair is covered before paying for parts. Benfolio reports Ford would not cover it, and that with under 100k miles they would have treated the repair as a goodwill repair. The photo shows the instrument cluster odometer.
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Step 3
Source a replacement manifold. Since Ford was not going to help, Benfolio did the job himself with a Dorman PI replacement that has an aluminum crossover. The two photos show the engine bay with the original plastic intake still on the engine.
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Step 4
Expect a big, messy job. Benfolio describes it that way. The first photo shows the car with the surrounding parts removed from the engine, and the second shows the engine valley with the old intake off and coolant standing in it.
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Step 5
Inspect the removed manifold to find the leak. Benfolio reports the crack was very small, barely dripping at idle or light throttle but gushing above 25% throttle.
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Step 6
Clean the engine valley and mating surfaces before fitting the new part. The photo shows the area cleaned up and ready for the new intake.
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Step 7
Set the new intake into place. The photo shows the replacement manifold going in.
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Step 8
The last photo shows the finished job with the engine reassembled. Benfolio reports it took about the time Ford's warranty says it takes, and that the 'crash bracket' was the part he most wanted to throw out a window.
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