Right Side

REMOVAL
1. Disconnect ignition wire from ignition coil and ignition wires from spark plugs.
2. Disconnect EGR valve to exhaust manifold tube from exhaust manifold.

NOTE: On California/Greenstate vehicles, disconnect the secondary air injection manifold tube from exhaust manifold.

3. Remove retaining nuts and remove engine lifting eye and heater water hose.
4. Raise vehicle on hoist.
5. Remove exhaust manifold-to-dual converter Y-pipe retaining nuts.
6. Remove heated oxygen sensor (HO2S).
7. Lower vehicle.
8. Remove exhaust manifold retaining bolts and stud bolts. Remove exhaust manifold and exhaust manifold gasket.

NOTE: Note location of stud bolts prior to removal.

INSTALLATION
1. Clean mating surfaces on exhaust manifold, cylinder head and dual converter Y pipe.

NOTE: Lightly oil all bolt and stud threads before installation except those specifying special sealant with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

2. Position exhaust manifold gasket and exhaust manifold on cylinder head. Install retaining bolts loosely.
3. Start remaining exhaust manifold retaining bolts and stud 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).

4. Connect EGR valve to exhaust manifold tube and if equipped, secondary air injection manifold tube.
5. Tighten exhaust manifold retaining bolts and stud bolts to 30-36 Nm (23-26 ft. lbs.).
6. Raise vehicle.
7. Connect dual converter Y pipe to exhaust manifold. Tighten retaining nuts in sequence to 21-32 Nm (16-23 ft. lbs.).

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.

8. Install heated oxygen sensor.
9. Lower vehicle.
10. Install engine lifting eye 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.).

NOTE: On California/Greenstate vehicles, connect the secondary air injection manifold tube.

12. Connect ignition wires to spark plugs.
13. Connect ignition wire to ignition coil.
14. Start engine and check for exhaust leaks.