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Exhaust Manifolds: Installation

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  1. Clean mating surfaces of manifolds and cylinder head. Lightly coat mating surfaces with graphite grease. If installing new exhaust manifolds, install exhaust manifolds without gaskets. Install new intake/exhaust manifold gasket on cylinder head.
    NOTE: The EGR valve to exhaust manifold tube is only on the rear exhaust manifold. If installing original exhaust manifolds, install NEW exhaust manifold gaskets.
  2. Position lower intake/exhaust manifold assembly on cylinder head. Ensure gasket remains in position. Tighten bolts and nuts in sequence to specification. See Fig 1. See TORQUE SPECIFICATIONS .
    Fig 1: Lower Intake & Exhaust Manifold Tightening Sequence
    G00593743Courtesy of FORD MOTOR CO.
  3. Connect power brake vacuum line. Connect dual converter Y pipe to the front and rear exhaust manifolds. Tighten lockwashers and nuts to 34-49 Nm (25-36 lb-ft).
  4. Install generator mounting bracket and three bolts finger-tight. Install nut finger-tight. a. Tighten bottom rear bolt to 30-40 Nm (22-30 lb-ft). b. Tighten center bolts to 30-40 Nm (22-30 lb-ft). c. Tighten nut to 30-40 Nm (22-30 lb-ft). d. Tighten bottom front bolt to 30-40 Nm (22-30 lb-ft).
  5. Install secondary air injection pump and tighten top bolt to 28-42 Nm (21-31 lb-ft). Tighten bottom bolt to 41-54 Nm (30-39 lb-ft). Install secondary air injection pump pulley and tighten screws to 12-15 Nm (9-11 lb-ft). Connect air pump hoses.
  6. Install generator and tighten bottom bolt to 53-72 Nm (39-53 lb-ft). Tighten top bolt to 22-28 Nm (16- 21 lb-ft). Connect generator wiring. Position drive belt.
  7. Using 3/8-inch flex handle, rotate drive belt tensioner and place accessory drive belt. Slowly release drive belt tensioner onto drive belt tensioning drive belt. Install heat shield and two clips.
    8. Fig 2: Heat Shield and clips
    G00593743Courtesy of FORD MOTOR CO.
  8. Reconnect all vacuum lines. Install the upper intake manifold and throttle body.
  9. Connect fuel lines to fuel injection supply manifold. Connect two heated oxygen sensors.
    Fig 3: Heat Oxygen Sensors
    G00593744Courtesy of FORD MOTOR CO.
  10. Connect engine control sensor wiring to powertrain control module. Connect the accelerator cable to the throttle body. Install accelerator control splash shield.
  11. Install air cleaner outlet tube and PVC air inlet hose at the crankcase vent filter. Connect battery ground cable.
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