How to replace 4.6 Exhaust Manifold on 2005 ford explorer?

4.6L Engine
SOHC & DOHC Engines
Left Side

Fig. Left side exhaust manifold and related parts-4.6L SOHC engine

Fig. Left side exhaust manifold torque sequence-4.6L SOHC Engine

Fig. Left side exhaust manifold and related parts-4.6L DOHC engine

1. Before servicing the vehicle, please familiarize yourself with safety procedures.
2. Remove or disconnect the following:
   
   
   Front fender splash shield

   Engine oil runoff

   Lower steering column shaft pinch bolt. Position the lower steering column shaft aside.

   Exhaust manifold heat shield

   8 nuts and the exhaust manifold

   To install, reverse the removal procedure. For the SOHC engine, tighten the nuts in the sequence shown. There is no torque sequence given for the DOHC engine.

Right Side

1. Before servicing the vehicle, please familiarize yourself with safety procedures.
2. Remove or disconnect the following:
   
   
   Front fender splash shield

   Heater control valve bracket bolt

   Vacuum hose and heater hose. Position the heater control valve assembly aside.

   Exhaust manifold heat shield

   Exhaust gas recirculation tube from the exhaust manifold

   Eight nuts and the exhaust manifold
   
   

   

   

   Fig. Right side exhaust manifold and related parts-4.6L SOHC engine

   
   
   

   

   

   Fig. Right side exhaust manifold torque sequence-4.6L SOHC engine

   
   
   

   

   

   Fig. Right side exhaust manifold and related parts-4.6L DOHC engine
3. Installation is the reverse of removal. For the SOHC engine, tighten the exhaust manifold nuts in the sequence shown. There is no torque sequence given for the DOHC engine.

VIN H Engine
Left Side

1. Before servicing the vehicle, refer to the -Precautions- section.
2. Remove or disconnect the following:
   
   
   Intermediate steering shaft

   LH front wheel and tire

   LH front fender well

   Y-pipe from manifold

   Heat shield

   LH exhaust manifold and gasket
   
   

   

   

   Fig. Left side exhaust manifold and related parts-2005 Aviator 4.6L (VIN H) engine

To install:

1. Install the exhaust manifold, with a new gasket and nuts. Tighten the nuts to 15 ft. lbs. (20 Nm).
2. Install or connect the following:
   
   
   Heat shield

   Y-pipe to manifold, with new nuts; tighten the nuts to 15 ft. lbs. (20 Nm)

   LH inner fender well

   LH tire and wheel

   Intermediate steering shaft

Right Side

1. Before servicing the vehicle, refer to the -Precautions- section.
2. Remove or disconnect the following:
   
   
   Tire and wheel

   Front inner fender well

   Y-pipe from manifold

   EGR tube from manifold

   Heat shield

   Manifold and gasket
   
   

   

   

   Fig. Right side exhaust manifold and related parts-2005 Aviator 4.6L (VIN H) engine

To install:

1. Position the exhaust manifold, with new gaskets, and tighten the new nuts to 15 ft. lbs. (20 Nm).
2. Install or connect the following:
   
   
   Heat shield; tighten the bolts to 8 ft. lbs. (11 Nm)

   EGR tube to the manifold

   Y-pipe to the manifold; tighten the new nuts to 15 ft. lbs. (20 Nm)

   Inner fender well

   Tire and wheel

VIN W & VIN 8 Engines
Left Side

1. Before servicing the vehicle, refer to the -Precautions- section.
2. Remove or disconnect the following:
   
   
   EVAP purge valve from the bracket and position aside (2006-07 models)
   
   

   

   

   Fig. Remove the EVAP purge valve from the bracket and position aside-2006-07 4.6L (VIN 8) engine

   Front fender splash shield

   Lower steering column shaft pinch bolt. Position the lower steering column shaft aside.

   Exhaust manifold heat shield

   8 nuts and the exhaust manifold
   
   

   

   

   Fig. Left side exhaust manifold and related parts-2005 4.6L (VIN W) engine

   
   
   

   

   

   Fig. Left side exhaust manifold torque sequence-2005 4.6L (VIN W) engine

To install:

1. Installation is the reverse of the removal procedure, noting the following:
   1. Tighten the nuts in the sequence shown as follows:
      
      
      2005: 15 ft. lbs. (20 Nm)

      2006-07: studs-9 ft. lbs. (12 Nm); nuts-18 ft. lbs. (25 Nm)
2. Tighten the Y-pipe new nuts as follows:
   
   
   2005: 15 ft. lbs. (20 Nm)

   2006-07: 30 ft. lbs. (40 Nm)
3. Tighten the intermediate shaft pinch bolt to 35 ft. lbs. (48 Nm).

Right Side

1. Before servicing the vehicle, refer to the -Precautions- section.
2. Remove or disconnect the following:
   
   
   Front fender splash shield

   EGR tube from the manifold (2005 only)

   RH transmission mount bolt (2005 only)
   
   

   

   

   Fig. Remove the RH transmission mount bolt to remove the Y-pipe-2005 4.6L (VIN 8) engine

   Y-pipe from the exhaust manifold

   Heat shield

   Eight nuts and the exhaust manifold
   
   

   

   

   Fig. Right side exhaust manifold and related parts-2005 4.6L (VIN W) engine

   
   
   

   

   

   Fig. Right side exhaust manifold torque sequence-2005 4.6L (VIN W) engine
3. Installation is the reverse of the removal procedure.
4. Tighten the exhaust manifold nuts in the sequence shown to the following:
   
   
   2005: 15 ft. lbs. (20 Nm)

   2006-07: studs-9 ft. lbs. (12 Nm); nuts-18 ft. lbs. (25 Nm)
5. Tighten the transmission mount bolt to 66 ft. lbs. (90 Nm) (2005 only)
6. Tighten the Y-pipe new nuts as follows:
   
   
   2005: 15 ft. lbs. (20 Nm)

   2006-07: 30 ft. lbs. (40 Nm)

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