Exhaust Manifold - LH: Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

All engines

Position the exhaust manifold gasket.

Fig 1: Positioning Exhaust Manifold Gasket
Courtesy of FORD MOTOR CO.

NOTE: 4.6L shown; 5.4L similar.

Fig 2: Installing Exhaust Manifold Nuts

Courtesy of FORD MOTOR CO.

Position the exhaust manifold and loosely install the nuts.

NOTE: 4.6L shown; 5.4L similar.

Fig 3: Tightening Nuts In Sequence

Courtesy of FORD MOTOR CO.

Tighten the nuts in the sequence shown in Fig 3.
Install the three-way catalytic converter to exhaust manifold nuts.

Fig 4: Identifying Three-Way Catalytic Converter To Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.

Windsor engine (5.4L)

Install the EGR valve fittings in two stages.
- Stage 1: Hand-tighten the fittings.
- Stage 2: Tighten the lower fitting to 50 Nm (37 lb-ft).
  
  Fig 5: Installing EGR Valve Fittings
  Courtesy of FORD MOTOR CO.
Connect the differential pressure feedback EGR sensor hoses to the EGR valve tube.

Fig 6: Identifying Differential Pressure Feedback EGR Sensor Hoses
Courtesy of FORD MOTOR CO.

Romeo engine (4.6L)

Install the EGR system module tube in two stages.
- Stage 1: Connect the upper and lower fittings and hand-tighten.
- Stage 2: Tighten to 40 Nm (30 lb-ft).
  
  Fig 7: Identifying EGR System Module Tube
  Courtesy of FORD MOTOR CO.

All engines

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