It's finally time to replace the gasket for the intake manifold. For some time now the car has been doing great with just the occasional blowout of the spark plug hole when the misfire would appear but I'm having to do it too frequently now.

Is there a write-up on how to do the DOHC specifically? I thought I found one at one time but I can't find it now. Other than the gasket set, new thermostat, and new spark plugs, is there anything else that needs replacing while I'm there? The car has 200k miles on it. I shouldn't need a new manifold correct? It's just the gasket?

 

Inspect the heater line that runs under the intake, it likes to rust and leak.

 

That's the one that's easiest just to cut and run a rubber line over it correct?

 

Yes, correct.

 

Alright, I'm working my way through the teardown.

I have the rear part of the upper intake off and most of the bolts for the rest of the upper off. What's the easiest way to get the two by the EGR off? The insulation makes my ratchet and socket not fit but I don't think I can get my closed end wrench in there and get enough torque to break them loose.

Also, I'm sure the gasket is causing the problem of my spark plug cylinder filling up, based on reading threads online, but I can't visualize how the coolant is making its way in there as I look at how the intake attaches to the engine. Can someone describe or picture the layout?

While I had a break I wanted your advice on the condition of this tube. It looks like it's in pretty good shape and I'd almost feel bad cutting it for not as good of a connection.

 

And a write up, for the remainder, would make me the happiest boy on Earth, if anyone knows of one.

 

I've read some more trying to picture in my mind how this can happen on this engine. I see how the water/coolant can get in there on the 2 valve engine but I can't see it from a leaking intake on this engine. It has happened more than one time and it does feel like coolant, but are these trucks known for the hood cowl leaking water into the plug wells too or some other leak getting coolant into the #8 well? Or is this 100% the intake manifold gasket? I have the rear portion of the upper intake off and I don't know if I should continue or not. I am starting to doubt myself.

 

There aren't any drips under the car, but there is a little bit of coolant loss over time. I'm going to take the upper plenum off since there are only two blots left and the upper gasket set includes it, but I'm going to wait until I hear something on the lower. I need to reconcile this in my head before I go for that. The difference in gasket sets is like $40 so I'd like to avoid buying the lower if there's no reason for it.

 

Inside lower intake manifold, Cyl. 8. If you can tell anything.





When I removed the coil cover, this is what the seal looked like



Maybe water got in?

#8 coil area





Video still of the #8 plug dwell





Dwell 5 for comparison



Going to post the videos as they upload to see if anything noticeable shows up.

 

What is the name of the piece that separates from the rear of the upper manifold that has the two square gaskets? Can I buy only those two square gaskets? So far those are the only two I need. Since I haven't heard anything from anyone I guess the car is going back together.

 

Though maybe I had a leak in the windshield washer line or something so I ran it a couple of times to see if it was dripping. The line i dry but I watched where the water ran down the cowl after and maybe there is something here?

Under the cowl, right over the driver's cylinder head.



The darker spot is water running down.

Now, I know the wire harness cover has a foam strip to seal against the metal there, but maybe it's finding its way down there somehow?

 

I have it for the 2003 not the 2002, but I suspect it's the same.

 

If the tube appears to be in good shape then by all means let it be. No need to create problems.

 

i have for a 2002 Lincoln Naviagor 5.4 4valve engine
don't have option to attached file so i have uploaded to my server.

http://www.dezign-worx.com/download/...5_4_engine.pdf

alloro if you can download and attached to this thread for future references.
server location is temporary.
thanks

 

Sure do make it look easy when they don't show the .25" of clearance you have to get back to those EGR bolts.