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Exhaust Manifold LH: Installation

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

    ALL ENGINES 

  1. Position the exhaust manifold gasket (9448).
    Fig 1: Installing Exhaust Manifold Gasket
    G01536442Courtesy of FORD MOTOR CO.
  2. Position the exhaust manifold and loosely install the nuts.
    Fig 2: Installing Exhaust Manifold
    G01536443Courtesy of FORD MOTOR CO.
  3. Tighten the nuts in the sequence shown.
    Fig 3: Identifying Nuts Tightening Sequence
    G01536444Courtesy of FORD MOTOR CO.
  4. Install the three-way catalytic converter to exhaust manifold nuts.
    Fig 4: Installing Three-Way Catalytic Converter To Exhaust Manifold Nuts
    G01536445Courtesy of FORD MOTOR CO.

    5. WINDSOR ENGINE (5.4L) 

  5. Connect the exhaust manifold to EGR valve fittings in two stages.
    • Stage 1: Hand-tighten the fittings.
    • Stage 2: Tighten the lower fitting to 40-60 Nm (30-44 lb-ft).
    Fig 5: Connecting Exhaust Manifold To EGR Valve Fittings
    G01536446Courtesy of FORD MOTOR CO.

    6. ALL ENGINES 

  6. Install the front fender splash shield (16103).
  7. Lower the vehicle.

    8. WINDSOR ENGINE (5.4L) 

  8. Connect the upper connections of the exhaust manifold to EGR valve tube.
    • Tighten the fitting at the EGR valve to 40-60 Nm (30-44 lb-ft).
    • Connect the hoses to the differential pressure feedback EGR system.
    Fig 6: Connecting Upper Connections Of Exhaust Manifold To EGR Valve Tube
    G01536447Courtesy of FORD MOTOR CO.

    9. ROMEO ENGINE (4.6L) 

  9. Connect the exhaust manifold to EGR valve tube in two stages.
    • Stage 1: Connect the upper and lower fittings and hand-tighten.
    • Stage 2: Tighten the fittings to 35-45 Nm (26-33 lb-ft).
    Fig 7: Connecting Exhaust Manifold To EGR Valve Tube
    G01536448Courtesy of FORD MOTOR CO.
  10. Install the differential feedback EGR system.
    • Install the system and hoses on the exhaust manifold to EGR valve tube.
    • Connect the electrical connector.
    Fig 8: Connecting Electrical Connector
    G01536449Courtesy of FORD MOTOR CO.

    11. ALL ENGINES 

  11. Install the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
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