Removal and Installation

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
Remove the air cleaner housing. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
Remove the 2 bolts and position the degas bottle aside.
- To install, tighten to 10 Nm (89 lb-in).
  
  Fig 1: Removing Bolts
  Courtesy of FORD MOTOR CO.
Remove the 4 exhaust manifold-to-catalytic converter nuts.
- To install, tighten to 40 Nm (30 lb-ft).
  
  Fig 2: Locating Exhaust Manifold-To-Catalytic Converter Nuts
  Courtesy of FORD MOTOR CO.
Disconnect and position the brake tube retainer aside.

Fig 3: Disconnecting Brake Tube Retainer
Courtesy of FORD MOTOR CO.
Remove the 10 nuts and the exhaust manifold.
- To install, tighten to 25 Nm (18 lb-ft) in the sequence shown.
  
  Fig 4: Removing Nuts And Exhaust Manifold
  Courtesy of FORD MOTOR CO.

CAUTION: 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.

NOTE: Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging.

Remove and discard the exhaust manifold gaskets. Clean the sealing surfaces with metal surface prep.
To install, reverse the removal procedure.