Attachment III - Technical Information
OVERVIEWThis program involves either:
A) inspecting the intake manifold part number to determine if the owner is eligible for reimbursement for a previous intake manifold replacement repair without a receipt, or
B) inspecting the intake manifold coolant crossover directly behind the alternator for leakage in the event the owner reports a suspected coolant leak. If a leak in this specific area is verified, the intake manifold must be replaced.
Proceed to the appropriate inspection procedure.
PART NUMBER INSPECTION
NOTE:
The part number is molded into the intake manifold and is located between two (2) runners on the driver side of the manifold. No disassembly is required to view the part number except for removal of the engine appearance cover, if equipped.
^ On most affected vehicles, the throttle body points toward the driver side of the vehicle. The part number will be found on the driver side of the manifold, beneath the throttle body intake tube.
^ On applications where the throttle body is pointing toward the right side of the vehicle, the part number is still located on the driver side of the manifold.
1. Remove the engine appearance cover, if equipped.
2. Locate the area on the intake manifold where the part number is to be found. See Figure 1.
3. NOTE: Thorough cleaning of the area is required in order to accurately read the part number prefix and suffix. Wrap a shop towel around the end of either a long screwdriver or long extension to reach the affected area to wipe after spraying with cleaner.
Clean the area between the two (2) runners by first blowing any dirt or foreign material away using compressed air. Then spray the area with Motorcraft Metal Brake Parts Cleaner, PM-4 or equivalent, and using a shop towel, wipe the area clean.
4. Read and record the intake manifold part number.
^ If the part number on the manifold matches the part numbers listed, the vehicle is not eligible for a refund without a receipt.
^ If the part number is different than the numbers listed below, the vehicle is eligible for a refund without a receipt.
COOLANT LEAKAGE INSPECTION
1. NOTE: To properly inspect the intake manifold you must look down behind the alternator. Inspect the coolant crossover area of the intake manifold as shown in Figure 2 for engine coolant leakage.
^ If seepage IS present, the intake manifold MUST be replaced. Refer to the appropriate Workshop Manual, Section 303-01 for 1996 through 1998 model year vehicles and Section 303-01 for 1999 through 2002 model year vehicles for replacement procedures for intake manifold.
^ If seepage is NOT present, no service action is required.