How to Replace the Exhaust Manifold in a Ford Explorer

The 2002 Ford Explorer kicked off the vehicle's current generation with new designs and options. A new 4.6L V8 offered 240 horsepower with a five-speed transmission and two or four-wheel drive. Here are the steps for the removal and installation of the exhaust manifold from the right side 4.6L SOHC and DOHC engines.

Instructions

Remove the Exhaust Manifold

1. Remove the front fender splash guard. Locate the bracket bolt for the heater control valve and remove it.

2. Disconnect the heater hose and vacuum hose. Remove the heater control valve assembly and set it aside.

3. Take off the exhaust manifold shield and then pull the exhaust gas recirculation (EGR) tube from the exhaust manifold.

4. Loosen and then remove the eight bolts holding the manifold in place. Lift the manifold out.

Install the Exhaust Manifold

1. Put the new exhaust manifold in place. Tighten the manifold nuts for the SOHC engine in sequence, starting at the front and alternating sides while working to the rear.

2. Torque to 30 foot pounds. Tighten the nuts for the DOHC to the same torque; there is no tightening sequence.

3. Reconnect the EGR tube to the manifold. Replace the exhaust manifold shield. Replace the heater control valve. Reconnect vacuum hose and the heater hose.

4. Set the heater control valve bracket in position and bolt it in place. Replace the front fender splash guard.

5. Start the engine. Check for exhaust leaks.

Tips & Warnings

• Make sure the engine and all components are completely cool before performing any repairs.