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

5

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.

6

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

7

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

8

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

9

Start the engine. Check for exhaust leaks.