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That bracket allegedly is also to protect the crossover for the fuel rails. I doubt it has any impact.

Anyway, you have an coolant temperature sensor and a coolant temerature sender, hence you have 2 sensors on the crossover. The 98+ have an integraded sender/sensor. You will be using both holes.


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Discussion Starter #62
Thank you!

So, is the one by the thermostat housing the 'sender"?

Is this the temperature sender switch?
https://www.autozone.com/engine-management/temperature-switch/duralast-temperature-switch/190440_656542_0_5835

And this would be the temperature sensor:
https://www.autozone.com/engine-management/coolant-temperature-sensor/duralast-coolant-temperature-sensor/136521_0_0

I wish there was an online parts reference for these cars.

So, it would seem that the ports in the crossover must be the correct sizes for each sensor.

Any idea about the space between the bracket mounts in the crossover, or the bolt sizes (8mm vs 10mm)?
 

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The thread is the same for both sensors so either one will fit in either hole. I cant find any info referencing which is which but I believe both are the same. One is for the ecu and the other one is for the gauge cluster. The first link is the correct part but the second one is supposed to be an intake air temperature sensor but the one pictured is not correct. Regardless its the wrong sensor. Do you still have your stock sensors? If you can salvage them I would just swap them over.

Also swap the bracket if you still have yours. Its odd that its a different size than stock but like I said aftermarket intakes are known to be inferior.

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Discussion Starter #64
I was just looking for a cheap intake that would stop the coolant leak. I am not going for performance. This is a point A to point B car.This car is going to become a backup soon anyways - if I can find a decent daily driver, at a good price. It has so much rust, and is using so much oil - that it's days are limited. Getting this car on the road again will enable me to shop for it's replacement

I will try to just swap the two sensors over into the new manifold.

I'm not sure this manifold is oem stock. I thought I read somewhere that ford didn't add the aluminum crossover until, maybe 2000, or so? And mine does have aluminum metal crossover, which means it may have been changed once already?

I will need to make sure either the old bracket can be retrofitted, or that the new bracket can be used - because those spark plug wires will need to be raised above the hot engine and alternator. I imagine that alternator gets pretty hot too?

(I looked at what replacing a rear seal entails - and it's beyond my ability - or my paying a mechanic as I imagine that would be pricey - if that is where the oil leak is, I thought it might just be the oil pan gasket - but even the oil pan cannot be lowered without major effort, I've been told).
 

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I didnt mean to come off as critical just stating a fact. I do understand and will not harp on it any longer.

The manifolds didnt change until 01 and yes it sounds like you got the updated one so it was changed at some point. Its a common failure for these cars.

The alternator will get heat soaked but I wouldnt worry about the heat on the spark plug wire. Though it could arc I guess. As long as the wires are kept away as best you can youll be fine.


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Discussion Starter #66
85ltd...No problems!

After I got the old manifold off, I found all kinds of debris in the cavity where the bottom of the manifold sits. There were even pieces of acorns in the debris! I guess some kind of rodent must of carried them in there! Here is a picture of the debris:

https://photos.google.com/share/AF1QipM1dBID6FHHFfm9eXMLzgt_8RFG9ETcTAROXWFJNTupX6CbYLMKlm3vVKtu_txaIQ/photo/AF1QipNiUyUrZ5MLNHwJpcqAdd6i8JFtyZNq0smcJYmv?key=c1hZZXZWTmFHZmpCSkVodklGOTN0MHlrZkxfZW9B

So, I finally have the old manifold out, and have cleaned up the surface area where the new manifold will go. I had a lot of build up around the engine ports (as can be seen in the picture above), but it looks pretty clean now. I used brake cleaner, and very fine steel wool, to clean the engine deck surface. There are still paper towels in each of the eight ports in this picture. (Should I just let the brake cleaner evaporate, or should I use something to 'neutralize' the brake cleaner? :

https://photos.google.com/share/AF1QipM1dBID6FHHFfm9eXMLzgt_8RFG9ETcTAROXWFJNTupX6CbYLMKlm3vVKtu_txaIQ/photo/AF1QipPGtMSNslKjEtO-LwQqZ0APNd7B4B2Pyduf0k8E?key=c1hZZXZWTmFHZmpCSkVodklGOTN0MHlrZkxfZW9B

I was surprised at how much black 'soot' is present in each of the eight 'air ports'. Is this typical? (The engine has about 213,000 miles):

https://photos.google.com/share/AF1QipM1dBID6FHHFfm9eXMLzgt_8RFG9ETcTAROXWFJNTupX6CbYLMKlm3vVKtu_txaIQ/photo/AF1QipNIQyRphQC4oMinWNgUA5HIvuP99hDKoLyxTJSe?key=c1hZZXZWTmFHZmpCSkVodklGOTN0MHlrZkxfZW9B

There is a small, black, plastic 'flap' at the end of the engine well. What is that for?

https://photos.google.com/share/AF1QipM1dBID6FHHFfm9eXMLzgt_8RFG9ETcTAROXWFJNTupX6CbYLMKlm3vVKtu_txaIQ/photo/AF1QipM_zWmWXDMLVC7c7hAjz3qLXtNV3BMn618zQPPg?key=c1hZZXZWTmFHZmpCSkVodklGOTN0MHlrZkxfZW9B
 

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Discussion Starter #67
Oh, and here is a picture of what failed on the old manifold. You can see a small piece of plastic that has broken, and is laying inside the aluminum port, which is just under the thermostat housing. You can also see a small piece of black gasket material - pushing out where that small plastic piece broke off. (This is a picture of the bottom side of the manifold:

https://photos.google.com/share/AF1QipM1dBID6FHHFfm9eXMLzgt_8RFG9ETcTAROXWFJNTupX6CbYLMKlm3vVKtu_txaIQ/photo/AF1QipPuNY6ZwVQSx-9IVP-AcBkMenZ8_d5_n8rBC3XM?key=c1hZZXZWTmFHZmpCSkVodklGOTN0MHlrZkxfZW9B

I am holding the plastic piece in this picture, and you cn see the gasket material that was protruding and letting the coolant spill out onto the engine deck and into the #5 spark plug well. Such a small thing to fail - and cause the engine to not be able to run! :

https://photos.google.com/share/AF1QipM1dBID6FHHFfm9eXMLzgt_8RFG9ETcTAROXWFJNTupX6CbYLMKlm3vVKtu_txaIQ/photo/AF1QipOaID2caTpdsZpFaSq76_2qWSHpUX4QYn5nhcOe?key=c1hZZXZWTmFHZmpCSkVodklGOTN0MHlrZkxfZW9B
 

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What brake cleaner that hasn't be cleaned up will evaporate o.k .The " flap " at rear of manifold valley I believe is what Ford call "converter inspection hole cover " .
 

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Discussion Starter #69
Good to know the brake fluid will evaporate..sure don't want anything degrading the gaskets on the new manifold.

What 'converter' is present that would be inspected? Is it part of the transmission?

Also, I just noticed that the new thermostat, that came with the new manifold, has an o-ring type thermostat seal.

The old thermostat, had a seal that looked more like a wider, flatter, rubber washer.

Should I be concerned at all about the difference in the way the new seal looks, or will perform, versus the old seal?

Is the new thermostat a good one?


Also, what is that hose/tube that runs along the bottom of the engine cavity from the front to back. Is that for coolant?
 

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What 'converter' is present that would be inspected? Is it part of the transmission?

Yes , torque convertor

......................

Should I be concerned at all about the difference in the way the new seal looks,

What was supplied with manifold should be fine .

You would benefit greatly by buying yourself a Haynes / Chilton or similar workshop manual or download .
 

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Discussion Starter #71
Well, the new intake manifold is now installed. Yeah. No more coolant leak. I did have to tighten up the temperature sensors a couple of times to get them to stop seeping - but now there is no further leaking.

I did have a bit of a scare after I got done and tried to start the engine. It would not turn over - until after several attempts. I think I had coolant in the 4 cylinders on the drivers side of the engine. I think that as the car sat in the driveway for a few days while I was waiting to get my new intake manifold that coolant kept leaking, and got into each spark plug well. Then probably into the cylinders. I did see coolant on the boots, and a little in the spark plug wells - that I thought I soaked up with some dry rags - but maybe some had already seeped past the spark plugs?

Anyways, here is some video of my first attempts to start it. The engine eventually turned over, but I am thinking that maybe I should have pulled the plugs and cranked a few times to 'spit out' any coolant after I first saw the engine was not turning over...

Engine not turning over:
https://photos.google.com/share/AF1QipM1dBID6FHHFfm9eXMLzgt_8RFG9ETcTAROXWFJNTupX6CbYLMKlm3vVKtu_txaIQ/photo/AF1QipPuSYd0yzlEWPFNij2eySNLR7J8hQJ2_eBIYV6R?key=c1hZZXZWTmFHZmpCSkVodklGOTN0MHlrZkxfZW9B

Almost starting:
https://photos.google.com/share/AF1QipM1dBID6FHHFfm9eXMLzgt_8RFG9ETcTAROXWFJNTupX6CbYLMKlm3vVKtu_txaIQ/photo/AF1QipMR-MBaYaa5sv4ghM3e-lRxdeJCf0FD3FxvMLxn?key=c1hZZXZWTmFHZmpCSkVodklGOTN0MHlrZkxfZW9B

Finally started:
https://photos.google.com/share/AF1QipM1dBID6FHHFfm9eXMLzgt_8RFG9ETcTAROXWFJNTupX6CbYLMKlm3vVKtu_txaIQ/photo/AF1QipPtFETQfF7C9eLwRfGQQ26DVity7kF3ccZnglFD?key=c1hZZXZWTmFHZmpCSkVodklGOTN0MHlrZkxfZW9B
 

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First video sounded like a " lazy " starter / bad bit on starter motor . But if o.k now it's ran , may have cleared .From what you say , double check no coolant in engine oil . Usual signs , emulsified oil or increase in oil level . Unlikely to be but better safe than sorry .
 
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