Water getting into coils, I cannot find a replacement engine cover anywhere

[MyExplorer03v8Lim]

This is a pretty simple request. My explorer didn't come with an engine cover when I purchased it used, and now that it's been snowing, water seems to be getting into the coil packs and causing misfires. --

Rather than fixing the symptoms, I want to stop the water getting into the area once and for all.

The engine in question is a 4.6 v8 on a 2003 limited explorer. I have looked all over the internet to the best of my ability and I have been unable to locate a replacement engine cover. Does anyone have one, or know where I can get one used? I haven't even checked the prices for new, but I imagine it's a very expensive hunk of plastic from ford.

 

[lincolnshibuya]

http://www.ebay.com/itm/2002-FORD-E...ash=item33c230921b:g:C54AAOSwKOJYGMjR&vxp=mtr

 

[Number Twelve]

Stupid question time: How does snow get on the engine with the hood closed?

I had a problem with rain getting in through the windshield wiper cowling fastener pins.

 

[MyExplorer03v8Lim]

Stupid question time: How does snow get on the engine with the hood closed?

I had a problem with rain getting in through the windshield wiper cowling fastener pins.

Well first off there are no stupid question. Let me start by saying that I haven't the first clue where moisture is getting in, so you're already one step ahead of me. To my mind, having all of the factory parts in the correct place is number one, while knowing where the water is entering becomes almost secondary. Of course I'd like to know how it's getting in, and I'm definitely going to work in tracking that down. But first I want to secure the cover and weatherstripping.

In regards to how snow would enter the engine compartment, I think the point you *may* be missing is that snow melts and becomes liquid water when daytime temperatures are higher than freezing and the sun is shining. So I am assuming that snow enters the engine compartment the same way rain does. even though I don't actually know where the moisture is getting into the vehicle from.

 

[ROBinGa]

Inspect the large radiator hose that connects to your intake mantifold. This is where your thermostat is and where water is entering the engine from radiator. Around the base of the part that connects the hose to the manifold do you see wetness? If so then I bet you have same problem as I currently have and many others have or will have. This part fails and leaks here allowing fluid to run along the top of engine to enter spark plug wells. I will be surprised if fluid is entering the spark plug causing misfires from any other source but this leaking manifold

 

[MyExplorer03v8Lim]

Inspect the large radiator hose that connects to your intake mantifold. This is where your thermostat is and where water is entering the engine from radiator. Around the base of the part that connects the hose to the manifold do you see wetness? If so then I bet you have same problem as I currently have and many others have or will have. This part fails and leaks here allowing fluid to run along the top of engine to enter spark plug wells. I will be surprised if fluid is entering the spark plug causing misfires from any other source but this leaking manifold

I HIGHLY suspect that you are correct. In fact I noticed that a tiny amount of coolant was leaking out of that hose. Furthermore, I mentioned this to the mechanic and it looks like he messed with the hose and might have either found and fixed a small dribble, or didnt find a dribble. He didnt mention it to me, and it doesn't look like he moved a lot around.

So what's the solution here?

 

[ROBinGa]

Changing out the entire intake manifold part. I just ordered one on eBay which was sold by a Ford Dealer in Nevada since for our 2003, the Dorman part does not fit our engine application. It was about $310 including shipping and I plan to change mine out this weekend. You will also probably need 3-4 gallons of new coolant unless you collect all you drain out and reuse and a new set of manifold gaskets which don't come with the Ford part. The Ford part number is 2L2Z9424AB for the manifold for a 2003 Explorer 4.6V8.

There are several writeups on here about doing this manifold change. Also a few YouTube videos although the orientation of EGR and throttle body may be different in the videos than our 2003 engine.

 

[MyExplorer03v8Lim]

Changing out the entire intake manifold part.

That's what I was hoping you wouldn't say.

I am aware of all the complaints with this intake manifold, and it's plastic construction. However I do believe that I already have the PI manifold with the metal thermostat part. I'm not sure what that part's called, but it's shaped like a wide horse shoe and spans from left to right across the top of the intake.

If it's really time to replace the entire intake manifold as you suggest, I'm wondering if it's time to consider an upgrade rather than an OEM replacement. Hell, maybe a supercharger!

 

[mountaineer2004]

Like NumberTwelve, water was leaking in through the windshield cowl fastener pins and killing both #4 and #8 coils. I siliconed those mofos real good, tested with water, and all's been good since. Stupid design.

 

[IIGood]

[QUOTE="MyExplorer03v8Lim, post: 3587213, member: 306967"However I do believe that I already have the PI manifold with the metal thermostat part. I'm not sure what that part's called, but it's shaped like a wide horse shoe and spans from left to right across the top of the intake.![/QUOTE]

That doesn't matter...the rest of the intake manifold is still plastic and can crack...as evidenced with my 2003 Mustang GT. That has the plastic intake with the metal crossover from the factory, and a few years back my intake cracked right where it meets the metal crossover. Just some food for thought.

 

[SyberTiger]

That's what I was hoping you wouldn't say.

I am aware of all the complaints with this intake manifold, and it's plastic construction. However I do believe that I already have the PI manifold with the metal thermostat part. I'm not sure what that part's called, but it's shaped like a wide horse shoe and spans from left to right across the top of the intake.

If it's really time to replace the entire intake manifold as you suggest, I'm wondering if it's time to consider an upgrade rather than an OEM replacement. Hell, maybe a supercharger!

Are you talking about he aluminum coolant crossover? That's actually a part of the intake manifold. At one time that crossover was made out of plastic but they redesigned it to be aluminum to strengthen it to support the weight of the alternator. My 2002 already came with the aluminum crossover therefore they apparently went to aluminum before that. At the rear of the intake there is also another coolant crossover molded into the intake manifold. Just because it's made of composite plastic doesn't mean that is where the failure is. The gaskets probably fail before the plastic in many cases.

BTW, which COP on which cylinder numbers do you think are a problem? All of them or specifics ones?