I had seen one before and would have lost on a bet of what is made of. You are right, plastic bolted on an engine who would have thought it so. That is just wrong.
Need engine part identified
- Thread starter GaExpedition
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I had seen one before and would have lost on a bet of what is made of. You are right, plastic bolted on an engine who would have thought it so. That is just wrong.
GaExpedition
Full Access Members
Got her all back together, but have one issue. she lopes like it has a cam at idle, smells like sulfur at the exhaust, and is throwing a PO402 code. I know I crinkled up the egr valve gasket a little, but wonder if that could cause that code? other than that, everything went smooth.
stamp11127
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GaExpedition
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I feel a little dumb admitting this, but I found my mistake that made it throw the code. I went back through the photos I took as I worked on it today and noticed I had accidentally put the red vacuum line that should have attatched to the fuel rail on to the egr valve, and the green vac line on the fuel rail. Put them back correctly, disconnected the battery for a bit, hooked battery back up, fired her up and she purrs like she should now. Thanks to everyone who posted.....especially the pictures. Those were huge! 
I feel a little dumb admitting this, but I found my mistake that made it throw the code. I went back through the photos I took as I worked on it today and noticed I had accidentally put the red vacuum line that should have attatched to the fuel rail on to the egr valve, and the green vac line on the fuel rail. Put them back correctly, disconnected the battery for a bit, hooked battery back up, fired her up and she purrs like she should now. Thanks to everyone who posted.....especially the pictures. Those were huge!
Glad it worked out for you...
I feel a little dumb admitting this, but I found my mistake that made it throw the code. I went back through the photos I took as I worked on it today and noticed I had accidentally put the red vacuum line that should have attatched to the fuel rail on to the egr valve, and the green vac line on the fuel rail. Put them back correctly, disconnected the battery for a bit, hooked battery back up, fired her up and she purrs like she should now. Thanks to everyone who posted.....especially the pictures. Those were huge!
Glad the pix helped. You are more than welcome. Glad I could help and really happy it worked for you and that it is really running great.
exceldetail
Well-Known Member
Wow, lucky I found this when I did. It appears I have the identical problem. I cannot believe the part I need to replace is plastic, maybe its been replaced before? It REALLY looks like aluminum. I was hoping it was just a paper gasket underneath. Problem all started a couple weeks ago when I began to smell radiator fluid. I monitored the levels and didnt see any noticeable drop, I attributed it to the hot weather we have been having and assumed it was an overflow. Tonight when I went to the store, I noticed the smell even more so, and decided to check it when I hot home. I did notice it was running just a tad hotter, but cooled down once on the freeway. When I got home to check where it was coming from, I could hear a slight gurgling at what I guess is the manifold where the hose connects? I checked the reservoir, EMPTY!
Not looking forward to this repair, any tips from any experts appreciated in advance.
Just follow the hose as it comes away from the firewall, and heads south. Its the apparatus it connects to, is where it appears to be leaking.
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GaExpedition
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Yeah, the aluminum piece the hose attaches to that your referring to, is attached to a black plastic intake manifold. You can google search 5.4 plastic manifold and get all kinds of info on them failing. I replaced mine with a Dorman plastic manifold because they redesigned it and made it better than fords original. I am not a mechanic by any means, but I enjoy working on mechanical things, and this job wasn't bad at all. I took my time, several breaks, lunch, and total time on it was 5 hours just using a standard socket wrench...no air tools. I also took pictures all the way through just in case I needed to refer back to them. Off the top of my head I used a 7mm socket, 8mm socket, 10mm socket, flat head screwdriver, several different length extensions, 1/4 drive ratchet, 3/8 drive ratchet, swivels for both, torque wrench, a special brush that fits in a drill to clean the surface area, some purple power, a small wet/dry vac, something stable to stand on to reach the back of the motor easier, and a couple of old rags. A couple of things I would say to look out for is be sure not to lose the o-rings on the injectors, once the old manifold is out be sure there is no coolant at the bottom of the spark plug holes...if there is be sure to remove it or it may cause a misfire. And the biggest warning of all is to be sure not to drop anything down into the motor while the manifold is off.
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exceldetail
Well-Known Member
Thanks for you help!
GaExpedition
Full Access Members
Have you done yours yet?
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