I don't remember a coolant hose under the intake, but has been awhile since I have done that job. Anyway, if you are losing coolant in that area, the '96 still has the old intake with the plastic by-pass from the thermostat housing across the top of the intake. Problem with these models is that the plastic cracks and you then have loss of coolant. This loss could be outside or inside into the intake. Most models I have seen leak to the outside, therefor you can see it. Ford is aware of this problem, they have produced a modified intake with a cast cross-over. Cost is anywhere from $ 500. to $ 700. just for the intake. The labor takes around 5 to 8 hours, depends on your skill. Up to around 2004 or so, Ford would only replace police and taxi models. They would not protect the regular sedan. Too bad, maybe that's why they are in this position today. If only they produced quality parts for their cars, and protected the major problems they would not be asking for billions to-day. If you take your car to Ford for the job, cost is around $ 1500.00. If you cannot do the job yourself, find someone who can, you will save lots of $$$$$, or if you live near me, then you would save also. Good luck.
The gasket is between the head and the intake.
Yes
lower intake manifold, 2 wire conector
you need manifold vacuum for the brake booster.. (intake manifold)
18 ft lbs
I'm not sure what you mean by a "diagram" but you can find detailed info on how to replace the intake manifold at the linke below... http://www.autoclinix.com/Manifold.htm Hope this helps.
No the 2001 Crown Vic does not have a aluminum intake , it has a composite plastic intake. as did all 96 to 01 Crown Vics. Starting in 02 Ford started using a different type of plastic intake with a aluminum front water crossover due to a class action lawsuit.
The intake manifold is an air intake. There isn't something that you refer to as a fuel intake. Fuel is introduced to the cylinders directly at the intake valves by the fuel injectors.
On a 4.6L engine, I have never seen a water hose under the intake. Anybody else?
Heater Core Return Hose. Stick to the factory one.
Remove the coil on top of the plug, and there is the spark plug.
This is about an 8 hour job. Start with draining the rad of coolant. You do not have to remove the fuel rail, just move it aside. Best is to take a picture of the intake before, gives you some reference to finish the job. Now, start with removing everything else that has to be removed. Torque the new intake to spec's.