Removal and Installation

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations.

Raise and support the vehicle.
On 4x4 vehicles, remove the front wheel opening moulding. Refer to FRONT END BODY PANELS .
Remove the front fender splash shield.
Remove the three way catalytic converter to exhaust manifold nuts.

Fig 1: Removing Three Way Catalytic Converter To Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
Remove the eight nuts and the exhaust manifold.

Fig 2: Removing Nuts And Exhaust Manifold
Courtesy of FORD MOTOR CO.
Remove and discard the exhaust manifold gasket.

Fig 3: Removing Exhaust Manifold Gasket
Courtesy of FORD MOTOR CO.
Clean and inspect the exhaust manifold; refer to ENGINE SYSTEM - GENERAL INFORMATION .
To install, reverse the removal procedure.
- Tighten the exhaust manifold nuts in the sequence shown
  
  Fig 4: Tightening Exhaust Manifold Nuts In Sequence
  Courtesy of FORD MOTOR CO.