Exhaust manifolds — removal and installation

1. Disconnect the exhaust pipes from the removed manifolds (chapter 4)

2. Remove spark plugs (Chapter 1).

Front manifold

3. Remove the screws from the dipstick tube bracket.

4. On 3.0L engines, disconnect the power steering hoses from the pump (chapter 10) and remove the cooling line support bracket (see picture).



5. Disconnect and remove the exhaust manifold from the vehicle (see picture).

Rear manifold

6. Disconnect the EGR pipe from the manifold (chapter 6).

7. On 3.0L engines, drain the cooling system (Chapter 1), remove the bracket that supports the heater tube and disconnect the heater hoses.

Only for 3.8L engines

8. Remove the air cleaner assembly and heater tube (chapter 4).


9. Disconnect the air intake hose from the check valve air tube below (chapter 4).

10. Remove the external heating cover from the exhaust manifold.

11. Remove the transmission dipstick tube.

12. Remove the lower tube of the air intake system. Use clamp cutters (type Ford T78R - 9481 - A or similar), to cut the tube clamp from the bottom of the body.

All engines

13. Disconnect and remove the exhaust manifold from the vehicle.

Installation

14. Thoroughly clean the gasket surfaces and check the manifold (s) for cracks and damage.

15. Lightly oil all bolts before installation.

16. Install the manifold in place on the cylinder head. On 3.8L models, do not forget the gasket. Install pivot bolt (on the left side it is the lower front bolt of cylinder #5. on the right - the lower rear bolt of cylinder No. 2).

Note: Slight misalignment of the exhaust manifold can cause misalignment of the bolt holes in the head and manifold.

Install the manifold so that the axes of the holes coincide without touching the pivot bolt.

17. Install the remaining bolts and studs at the connection points (see picture) and tighten to the required torque.









18. Install the remaining parts in the reverse order of disassembly.