Need some help with heater hose/placement issue

[Kenneth Kenny]

Hey folks, thanks in advance for indulging my ignorance, and for any help you may be able to give me. Today I got a 2003 Explorer 4.6 that is having several issues, among them being that the intake manifold heater hose connection is bare. I think at some point someone tried to rig something and just had it blocked off with a clamped hose or something.

Anyway, here's a pic. I can't figure out where the hose from the intake would go to. If anyone can tell me how to properly configure the heater/intake manifold coolant hoses I would really appreciate it. Feel free to post pics if possible or needed.

 

[IPcamper]

That looks like a Dorman replacement manifold for the 4.6L v8. The explorer doesn't use that coolant port on the manifold, and the original manifold doesn't even have the coolant port. Easiest thing to do is to put a short piece of hose on it and plug the end of the hose with a metal bolt/plug. Be sure to good hose clamps on it.

 

[Kenneth Kenny]

Thanks a lot for your help, that sounds about right. However upon further inspection I see that that coolant port (plastic of course) is cracked all the way down.

Does that mean time for a new intake manifold, or is that nipple removable/replaceable?

 

[IPcamper]

If it is cracked and leaking, you will need to replace the manifold. Not a hard job, a couple of hours at most.

 

[Kenneth Kenny]

Your help is appreciated very much.

I ordered a new manifold, but in the meantime I just broke off the top of the broken plastic port and "modified" an expansion plug to fit in there. So far so good, I let it run for 10-15 minutes and it held, don't know if I would trust it out and about though.....haha

 

[Kenneth Kenny]

UPDATE: Drove around for about 45 minutes or so (close to home, haha), the plug held up, engine temp never got over 190 degrees, and no noticeable leaking around that area. Still getting misfire codes, might try to change out the spark plugs soon. Hopefully this will hold up and I can put off replacing the manifold immediately.........

 

[IPcamper]

Which cylinder is misfiring? Sometimes when the intake manifold starts to leak coolant, it will leak into the cylinder intake and cause a misfire. My 03 explorer did this last year and the leak was at the intake manifold gasket.

 

[Kenneth Kenny]

I'm getting various misfire codes, P0308, P0306 and of course the lean codes. Pretty sure the intake gaskets need replacing but I'm hoping to put that job off a while!

 

[IPcamper]

If you are leaking coolant into the cylinder intake, it can damage the Catalytic converter. If so, do put the repair off too long.
Best of luck with it. There are numerous posts on this site for doing the replacement.