2002 4.6L intake replaced

stockxplorer · September 22, 2013

Does anybody know what the nipple is for on the Dorman replacement intake manifold for the explorer. I had the manifold replaced and the mechanic that put the new one on put a cap on it and told me to make sure it stays tight or it will blow off. It keeps blowing off and I'm tired of fooling with it! I'm wondering if it should have a hose connecting to it instead of just letting it keep building up pressure and eventually blowing off! I can't be the only one with this problem!!!!!

JoshMcMadMac · September 23, 2013

Can you get a picture? Where is it located on the manifold?

Juggernaut31 · September 23, 2013

on the passenger side rear? if so, that is indeed a water hose that runs to the heater core.

HiImBrian · September 24, 2013

I'm having the same issue with my bullitt intake. The stock intake did not have that coolant tube so the intake just kind of capped it. Now that my intake has a tube there I need to tie it in to the coolant system. I'm just not sure where to tie it in. I don't know if it is a coolant inlet or a return. Right now it's just capped.

dwilly99 · September 24, 2013

the dorman cap has blown off mine twice in about a year, so what i did was cut about a 6-8in 3/4in heater hose, hose clamped a 3/4in bolt in one end and sanded the nipple on the intake a little bit to give is some grip then hose clamped the hose to the intake

HiImBrian · September 24, 2013

For that much effort, you could have tapped into a cooling line and actually used it for it's purpose rather than capping it off. That's what I intend to do, as soon as I find out whether it needs to flow into that tube or out of it.

esclamada · September 25, 2013

that outlet was meant for other models other than the explorer (grand marquis/crown vic) where the heater hose goes through. The dorman has instructions that it should be plugged.

I used the aluminum plug (provided) and then use a hose cap with clamp (at advance auto) to prevent it from leaking. The aluminum plug can't seal it completely, putting that and tightening it with the clamp will prevent that outlet from cracking if tightened incorrectly.

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20EddieBauer02 · March 21, 2014

The rubber plug on mine has blown apart 4 times now, last week my fiance was by herself when it happened, so now I need it right, can't have that happening again. plan on trading it but hate to since its still immaculate for an 02'.
Did any of you Tee it into the heater core line? I am planning to bull plug the threaded part on the thermostat housing and just using that back port for the heater core. Any ideas on how well/ if it would work?

extsp2 · March 22, 2014

I also put that plug into the hole and used the cap that Dorman had on there but used a real hose clamp and it's stayed on for a couple weeks now.

HiImBrian · March 24, 2014

20EddieBauer02 said:
The rubber plug on mine has blown apart 4 times now, last week my fiance was by herself when it happened, so now I need it right, can't have that happening again. plan on trading it but hate to since its still immaculate for an 02'. Did any of you Tee it into the heater core line? I am planning to bull plug the threaded part on the thermostat housing and just using that back port for the heater core. Any ideas on how well/ if it would work?

I had the exact same problem with my ported Bullitt intake and just T'd it into the heater core. 4 months and no problems so far. And you're right, those little rubber caps blowing out is damn annoying.

2002 4.6L intake replaced

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