Removing the exhaust manifold (Escort 5)

Removal

All engines except Zetec and Zetec-E

Remove the negative terminal from the battery.

The exhaust manifold is attached to the cylinder head with studs and nuts. The hot air intake is bolted to the exhaust manifold. To access the exhaust manifold mounting nuts, it is necessary to remove the hot air intake (see Fig. 4E.7-4E.9).







On vehicles equipped with an air pulse system, remove the air pulse line. If there is an oxygen sensor, disconnect the connector and remove the sensor.



Support the exhaust inlet pipe with a jack or suitable stands and unscrew the nuts securing the exhaust inlet pipe to the manifold. Disconnect the pipe from the manifold and remove the gasket. Unscrew the fastening nuts and remove the manifold from the cylinder head studs. Remove the manifold gasket (see Fig. 4E.10, 4E.11).

Zetec and Zetec-E engines

Remove the negative terminal from the battery. Remove the air supply pipes to the engine. Drain the coolant from the cooling system. Disconnect the coolant supply hoses to the thermostat housing.

Unscrew the bolt securing the heated air intake from the exhaust manifold and remove it (see Fig. 4E.12).



Loosen the bolt on the air filter housing and disconnect the vacuum hose of the air pulse system or remove this system completely (see Fig. 4E.13).





Disconnect the connector from the oxygen sensor wire. Unscrew the nuts and disconnect the exhaust inlet pipe from the manifold.

Unscrew the nuts and remove the exhaust manifold together with the gasket (see Fig. 4E.14).



Always use a new gasket when installing the exhaust manifold.

Examination

Using a scraper, remove any remaining old gasket and carbon deposits from the manifold and cylinder head.

On some models, the exhaust manifold is secured to the exhaust manifold by two bolts with a coil spring and a self-locking nut. When installing, tighten the nuts until they are seated on the bolt shoulders. In this case, the spring pressure will ensure a tight connection (see Fig. 4E.15-4E.17).

Installation

Installation is carried out in the reverse order of removal, taking into account the following points:

• install a new exhaust manifold gasket onto the cylinder head studs and on Zetec and Zetec-E engines install a new plastic guide sleeve onto the stud closest to the thermostat housing to properly seat the manifold. Do not install the manifold without this sleeve (see Fig. 4E.18);
• install the manifold and screw on the mounting nuts;
• working from the middle in 3-4 steps, tighten the manifold mounting nuts to the required torque;
• install the remaining parts in the reverse order of removal;
• if necessary, add coolant to the cooling system;
• start the engine and check the exhaust system for leaks.

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