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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 973 (Engine - 5.4L (3V) - F150 Pickup) >> In-Vehicle Repair >> Exhaust Manifold - RH >> Installation

Exhaust Manifold - RH: Installation

WARNING: This page is about a different car, the 2005 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. Clean and inspect the exhaust manifold for flatness. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION -- F150 PICKUP
    2. NOTE:

    NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces. 

  2. Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging.
  3. Install 4 new upper exhaust manifold-to-cylinder head studs.
    • Tighten to 12 Nm (106 lb-in) 
  4. Install the RH exhaust manifold gaskets and RH exhaust manifold.
  5. Install the 4 new upper exhaust manifold nuts.
  6. Install 4 new lower exhaust manifold-to-cylinder head studs.
    • Tighten to 12 Nm (106 lb-in) 
  7. Install the 4 new lower exhaust manifold nuts.
  8. Tighten the 8 exhaust manifold nuts to 25 Nm (18 lb-ft) in the sequence shown.
    Fig 1: Identifying Exhaust Manifold Nuts With Tightening Sequence
    G00520124Courtesy of FORD MOTOR CO.
  9. Position back the A/C compressor and install the 3 A/C compressor bolts.
    • Tighten to 25 Nm (18 lb-ft) 
  10. Install the RH inner fenderwell. For additional information, refer to BODY PANEL SYSTEM -- FRONT END BODY PANELS -- F150 PICKUP
  11. Lower the engine.
    12. IMPORTANT:

    Only use hand tools when installing the LH engine mount bolt or damage to the engine mount can occur. 

    Fig 2: Identifying LH Engine Support Insulator Bolt
    G00520125Courtesy of FORD MOTOR CO.
  12. Apply threadlock to the threads and install the LH engine support insulator bolt.
    • Tighten to 350 Nm (255 lb-ft) 
    13. IMPORTANT:

    Only use hand tools when installing the RH engine mount bolt or damage to the engine mount can occur. 

    NOTE: Make sure the RH engine support insulator mating surfaces and the washer mating surface are free of foreign material and corrosion before installation. Install a new washer. 
    Fig 3: Identifying RH Engine Support Insulator & Fasteners
    G00520126Courtesy of FORD MOTOR CO.
  13. Apply threadlock to the stud threads and install the 2 RH engine support insulator washer and nuts.
    • Tighten to 250 Nm (184 lb-ft) 
  14. Install the starter. For additional information, refer to STARTING SYSTEM -- F150 PICKUP
  15. Tighten the 2 transmission mount nuts.
    • Tighten to 103 Nm (76 lb-ft) 
      • Fig 4: Identifying Transmission Mount & Fasteners
      G00520127Courtesy of FORD MOTOR CO.
  16. Install the 2 exhaust Y-pipe-dual catalytic converter hanger bracket bolts to the crossmember.
    • Tighten to 40 Nm (30 lb-ft) 
      • Fig 5: Identifying Exhaust Y-Pipe-Dual Catalytic Converter Hanger Bracket Bolts
      G00520128Courtesy of FORD MOTOR CO.
    17. NOTE: RH shown LH similar.
  17. Install the 4 new exhaust Y-pipe flange nuts.
    • Tighten to 40 Nm (30 lb-ft) 
      • Fig 6: Identifying Exhaust Y-Pipe Flange Nuts
      G00520129Courtesy of FORD MOTOR CO.
  18. If equipped, position the skid plate and install the 4 bolts.
    • Tighten to 25 Nm (18 lb-ft) 
      • Fig 7: Identifying Skid Plate & Fasteners
      G00520130Courtesy of FORD MOTOR CO.
  19. Attach the cooling fan shroud to the bottom of the radiator and position the cooling fan shroud back to the radiator.
    • Install the 2 bolts 
    • Tighten to 10 Nm (89 lb-in) 
      • Fig 8: Identifying Fan Shroud & Fasteners
      G00520131Courtesy of FORD MOTOR CO.
  20. Install the upper radiator sight shield.
    Fig 9: Identifying Upper Radiator Sight Sheild
    G00520132Courtesy of FORD MOTOR CO.
  21. Install the generator. For additional information, refer to GENERATOR AND REGULATOR -- F150 PICKUP
  22. Position the power steering fluid reservoir and install the 3 bolts.
    • Tighten to 11 Nm (8 lb-ft) 
      • Fig 10: Identifying P/S Reservoir & Fasteners
      G00520133Courtesy of FORD MOTOR CO.
  23. Install the TB. For additional information, refer to FUEL SYSTEM & ENGINE CONTROLS - 5.4L (3V) -- F150 PICKUP
  24. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES -- F150 PICKUP
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