Ford F77Z-9430-HA Exhaust Manifold Assembly

Because the exhaust manifold is bolted to the engine block and attached to the catalytic converter and oxygen sensors, one has to follow these procedures, The negative cable on the battery has to be disconnected followed by lifting the car using jacks and placing it on jackstands. Coat the exhaust pipe and manifold fasteners with rust penetrant allowing it to stay for about 10 minutes; where there is more than usual resistance, re-coat the fasteners. Disconnect the exhaust pipe(s) at the manifold or manifolds, leaving the bolt of the flywheel attached to the pipe Secure the wires of the right side spark plugs. Open and take off the manifold, for the left side, quarter the nut holding the oil dipstick tube and either turn it or take it off fully. Disassemble the EGA tube, after that remove the manifold as well. For installation clean the flute of head and manifold and lightly lubricate the screw threads of all the nuts bolts etc. Incorporate the manifold with all the bolts being tightened just enough simultaneously from the middle to the ends of the bolt then torque the bolts. Replace all parts taken out for clearance, use ATV sealant on the base of the dipstick tube if this was done and push it into the block until it locks. That involves connecting the exhaust pipe to the manifold(s), to lower the car and reconnect the battery cable. Last of all, step on the accelerator and look for exhausts.

Remove the bolts securing the lower portion of the accessory drive bracket.

Check that the mating surfaces are perfectly flat and not damaged in any way. Warped or damaged manifolds may require machining.

Install the EGR line at the exhaust manifold.

Use a new gasket to install the manifold and the eight bolts attaching it to the cylinder head.