Right Side

REMOVAL
1. Disconnect ignition wire from ignition coil (12029) and ignition wires from spark plugs (12405).
2. Disconnect EGR valve to exhaust manifold tube (9D477) from exhaust manifold (9430).
3. Loosen retaining nut and remove heater inlet tube and heater water hose (18472).
4. Raise and support vehicle.
5. Remove exhaust manifold-to-dual converter Y-pipe retaining nuts.
6. Remove heated oxygen sensor (H02S)(9F472).
7. Lower vehicle.
8. Remove exhaust manifold retaining bolts. Remove exhaust manifold and exhaust manifold gasket (9448).

INSTALLATION

NOTE: Lightly oil all bolt and stud threads before installation except those specifying special sealant with clean engine oil meeting Ford specification WSS-M2C153-F.

1. Clean mating surfaces on exhaust manifold, cylinder head (60493 and dual converter Y pipe (5F250).
2. Position exhaust manifold gasket and exhaust manifold on cylinder head. Install two new retaining bolts loosely.

NOTE: A slight warpage in the exhaust manifold may cause a misalignment between the bolt holes in the cylinder head and exhaust manifold. Elongate the holes in the exhaust manifold as necessary to correct the misalignment. Do not elongate the pilot hole (lower rear bolt hole on No. 2 cylinder).

3. Start remaining exhaust manifold retaining bolts loosely.
4. Connect EGR valve to exhaust manifold tube loosely.
5. Tighten exhaust manifold retaining bolts and stud bolts to 30-36 Nm (23-26 ft. lbs.).
6. Raise and support vehicle.

NOTE: If a new exhaust manifold is being installed or a new dual converter Y-pipe-to-exhaust manifold retaining stud is required, install stud until seated securely on exhaust manifold.

7. Connect dual converter Y pipe to exhaust manifold. Tighten retaining nuts in sequence to 21-32 Nm (16-23 ft. lbs.).
8. Install heated oxygen sensor.
9. Lower vehicle.
10. Install heater inlet tube and heater water hose. Tighten retaining nut to 20-30 Nm (15-22 ft. lbs.).
11. Tighten EGR valve to exhaust manifold tube nuts to 34-47 Nm (25-34 ft. lbs.).
12. Connect ignition wires to spark plugs.
13. Connect ignition wire to ignition coil.
14. Start engine and check for exhaust leaks.