Ford BL3Z-9430-B Exhaust Manifold Assembly

Disconnect the cable from the negative battery terminal, then raise the vehicle and support it securely on jackstands. Disconnect the oxygen sensor electrical connector(s) and, while working under the vehicle, apply penetrating oil to the exhaust Y-pipe-to-manifold studs and nuts, as they are usually rusty. Remove the nuts holding the exhaust Y-pipe to the exhaust manifolds from below, and disconnect the EGR pipe from the exhaust manifold. Remove the engine lifting bracket, then take out the nut holding the oil dipstick tube support at the front of the manifold and pull the dipstick tube up and out of the oil pan. Next, remove the mounting nuts and separate the exhaust manifold(s) from the cylinder head, ensuring to remove the old gaskets. Check the exhaust manifold for cracks and ensure all stud threads are clean and undamaged, making sure the mating surfaces are clean before reinstalling the manifolds. If replacing the exhaust manifold with a new one, remove the oxygen sensor, clean its threads, and coat them with high-temperature anti-seize compound before transferring it to the new manifold. Position the exhaust manifold and new gasket on the cylinder head, install the mounting nuts, and tighten them in the correct order using a torque wrench, ensuring to tighten in three equal steps until the specified torque is reached. The remaining installation steps follow the reverse order of removal, after which start the engine and check for exhaust leaks.

The first step in removing the exhaust manifold, is to reduce the pressure in the fuel system for 6.2L or, discharge the A/C system on the 5.0L. Remove the negative battery terminal, properly support the car on jack stands and then remove the inner splash shield of the fenderwell. Pour penetrating oil on the studs and nuts of the exhaust pipe to manifold, and on the 4.6L engines, put penetrating oil also on EGA pipe fitting. Pull the EGR pipe out of its positions on the EGR valve and exhaust manifold and unbolt the exhaust Y-pipe or dual-catalyst Y-pipe nuts. In the case of car models containing engines using 3-valves, one has to unscrew the heat shield bolts in addition to the heat shield, and the eight kulak breathe nuts on the exhaust manifold. Move on to the next step, which is to take of the exhaust manifold and also the old gasket. They are the starter, nuts of the Y-pipe, and at times the drive belt for the right exhaust manifold where you have to reverse the above process. On the 5.4L engine, it is necessary to remove the heated oxygen sensors, the Y-pipe support bracket and the air intake duct if it is to be removed and the nuts and heat shield from the catalytic converter. For the 6.2L engine, support the engine from above, remove the nuts from the catalytic converter bracket, loosen the transmission-to-crossmember nuts, then, remove the nuts from the engine mount. This is done by first removing all old exhaust manifold studs and then ascertaining that the exhaust manifolds are free from cracks; clean the mating surfaces, put a new gasket and finally tightening the mounting nuts in an orderly manner. Last but not the least; connect back the EGR pipe using anti-seize compound and check whether there is any exhaust leak after starting the engine and charge the AC if necessary.

Disconnect the cable from the negative battery terminal. Loosen the wheel lug nuts on the side of the vehicle from which the exhaust manifold is to be removed, then raise the vehicle and support it securely on jackstands. Disconnect the oxygen sensor electrical connectors. Working under the vehicle, apply penetrating oil to the exhaust Y-pipe-to-manifold (or turbocharger) studs and nuts, as they are usually rusty. Remove the nuts holding the exhaust Y-pipe to the exhaust manifolds or turbochargers, and from below, remove the two exhaust Y-pipe-to-manifold nuts. Remove the wheel and the inner fender liner. For 3.5L engines, remove the turbocharger and then remove the two bolts to take off the exhaust manifold heat shield. Remove the manifold mounting nuts and detach the manifold from the cylinder head, noting that the manufacturer recommends removing the exhaust manifold mounting studs from the cylinder heads and installing new studs. Remove the exhaust gaskets and clean the gasket surfaces on the manifold and cylinder heads. Check the exhaust manifold for cracks and ensure all the stud threads are clean and undamaged, as the mating surfaces must be clean before reinstalling the manifolds. Position the exhaust manifold and new gasket over the studs on the cylinder head and install the mounting nuts. When tightening the nuts, tighten the center pair first, then the front pair, and finally the rear pair, to the specified torque. The remaining installation steps are the reverse of removal. Start the engine and check for exhaust leaks.