Lincoln F5AZ-9430-A Exhaust Manifold Assembly

Disconnect the cable from the negative terminal of the battery and unplug the electrical connector for the oxygen sensor. Remove the spark plug heat shields, if equipped, and the spark plugs. Raise the vehicle and support it securely on jackstands. While working under the vehicle, apply penetrating oil to the exhaust pipe-to-manifold studs and nuts, allowing the fluid to sit for as long as possible to loosen rusty parts. Remove the air cleaner assembly and heat stove tube, if equipped. For the right side manifold, take out the Thermactor hardware, if equipped, and the automatic transmission fluid dipstick tube if necessary, along with the exhaust manifold heat shield, if equipped. For the left side manifold, remove the engine oil dipstick and tube if it obstructs access. Bend back the locking tabs, if equipped, then remove the mounting bolts and separate the manifold from the head, noting the locations of the pilot bolts. Check the manifold for cracks and ensure the bolt threads are clean and undamaged, making sure the mating surfaces are clean before reinstalling. Position the manifold and gasket on the head and install the mounting bolts, tightening them from the center to the ends using a torque wrench in three equal steps until the specified torque is reached. Complete the remaining installation steps in reverse order of removal, then start the engine and check for exhaust leaks.

To remove the exhaust manifold first unplug the battery and then take the vehicle off the ground on jack stands. Soak the exhaust pipe to manifold studs and nuts with penetrating oil because they are usually severely rusted; then, undo the nuts fastening the exhaust pipe(s) to the manifold(s). If more force is required to break the nuts loose, the nuts can be heated using propane or acetylene torch. Remove the EGR tube connector from the right side manifold and two through bolts of engine mount. Slowly raise the engine with a floor jack to avoid stretching hoses and connections and with great care for the bulk of the wiper module, cooling fan and fuel lines. Should it be necessary, disconnect the lower engine mount on the left side to allow access to all bolts that are used to attach the exhaust manifold to the cylinder head The exhaust manifold(s) bolts to cylinder head(s) are then removed in order to separate the manifold from the cylinder head. For reassembly, inspect the manifold for cracks and be sure that the bolt threads are dry and both have no damage then clean the mating surfaces before replacing. Place the manifold on the head and fit the mounting bolts and as is always recommended use the torque wrench in steps to tighten the bolts from the center and ends. Last of all, turn on the engine and look for signs of exhaust.

For the left side manifold, remove the automatic transmission fluid dipstick tube if necessary. Also, remove the engine oil dipstick and tube if they are in the way.