Review on 🔧 Dorman 615-178 Intake Manifold for Ford, Lincoln, Mercury - Engine Component Selection by Joseph Hamilton

This is actually my second intake manifold replacement for my '98 Crown Victoria. The first thing you should know is that Dorman is not the only company that makes replacement intake manifolds. I believe Dorman either sold the instruments or the rights to their design. So if you see a cheaper version of this air intake, look at the pictures and the part number and think "Yes, it's exactly the same but with a different name painted on the front", you know it's not is the case.A unit I bought from another manufacturer (which uses part number 615-178X - note the "X") failed after three years of use.The plastic started to degrade and at the joint coolant started to leak at the metal junction with the plastic air intake housing. In addition, the non-original header was slightly warped and required care and attention to bolt it on properly. It worked great and saved me $60-$100. but three years later I'm doing it did the job again. Second, it's important to know that Dorman has changed its design. The new 615-178 has thicker intake ports and slightly different shaped ports and seals. Also em the mounting surface of the air intake physically shifts by several centimeters! It doesn't really change anything and doesn't cause any problems, but I've noticed it. Although all turned out well, here's what you should know: 1. This replacement header uses self-tapping screws instead of the bolts and brass inserts used in the original part. It's ok if you are careful when installing it. I recommend that you first drive the screws into their holes with no load, then remove them and *then* install brackets or whatever. You don't want a strut, spool, or other object causing the self-tapping screw to go in at an angle. You only get one chance at these things.2. The original header (and previous replacement!) included a bolt to attach the ground wire to the fuel rail. It is absent from this design. You must either replace the end of the ground wire with a ring that attaches to the fuel rail bolt, or strip the ground wire completely and leave it hanging from the firewall.3. While a replacement alternator bracket is included (which you will need), you may ALSO need to replace the front throttle cable bracket. It fits perfectly with the original header and fits perfectly with the old replacement design, but it won't fit this new one unless you drill out all three holes. They only moved the mounting bolt hole a few millimeters, just enough that it wouldn't fit without modification.4. Although a thermostat housing gasket is included, I didn't need it on my '98 Crown Victoria. Your vehicle may require it.5. The instructions are absolutely terrible. It's so useless they might not include it at all, other than the torque specs. Find instructions online. There are some very good and helpful ones. Follow them.6. USE A TORQUE WRENCH and FOLLOW THE INSTRUCTIONS for ordering, specifications and steps. The torque value given is very low, lower than expected, but this is a thin-walled plastic part. DO NOT overtighten or you will break it. That's all. Much luck. If you're careful and take your time (I spent six hours over two evenings) you shouldn't have any problems and you'll be on your way again. Just pay attention to these torque values, handle the bolts carefully and follow the instructions! Have fun driving!