Exhaust Manifold - LH: Installation

WARNING: This page is about a different car, the 2010 Ford Pickup, 2010 Ford F550 Super Duty, 2010 Ford F450 Super Duty, and 2010 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Position the new horizontal EGR cooler clamps and install 2 new pins.

Fig 1: Locating EGR Cooler Clamps Pins
Courtesy of FORD MOTOR CO.
Position the new gasket and the LH exhaust manifold. Loosely install the 4 new exhaust manifold bolts.
Position the horizontal EGR cooler bracket and loosely install the 4 new bolts.
Tighten the exhaust manifold bolts in 2 stages in the sequence shown in the illustration.
- Stage 1: Tighten to 25 Nm (18 lb-ft).
- Stage 2: Tighten again to 25 Nm (18 lb-ft).
  
  Fig 2: Identifying Exhaust Manifold Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Insert the horizontal EGR cooler locating pin into the slot in the horizontal EGR cooler bracket and install the 2 new clamp nuts. Tighten the clamps for the horizontal EGR cooler in 3 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Loosen the clamps 720 degrees.
- Stage 3: Tighten to 8 Nm (71 lb-in).
  
  Fig 3: Locating Nuts, Clamps And Horizontal EGR Cooler
  Courtesy of FORD MOTOR CO.
Position the steering shaft into the housing. Install the new steering shaft bolt.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 4: Locating Steering Shaft Bolt
  Courtesy of FORD MOTOR CO.
Position a new horizontal EGR cooler outlet gasket and install the 2 studs.
- Tighten to 17 Nm (150 lb-in).

NOTE: Do not bend or twist the Exhaust Gas Recirculation (EGR) cooler bellows or damage to the EGR cooler may occur.

NOTE: Inspect the corrugation of the vertical EGR cooler inlet to make sure that the corrugation ribs are not touching and are not damaged.

Install the 2 horizontal EGR cooler outlet nuts.
- Tighten to 31 Nm (23 lb-ft).

NOTE: The coolant hose clamps used on this engine are constant tension worm gear clamps. Standard worm gear clamps cannot be used. Failure to use the correct coolant hose clamps may result in hose joint failure.

Using a new clamp, connect the EGR cooler coolant outlet hose to the horizontal EGR cooler.
- Tighten to 4 Nm (35 lb-in).

NOTE: Install a new O-ring seal and clamp on the coolant supply tube.

NOTE: Position the flexible section of hose on the EGR cooler prior to installing the tube.

NOTE: Make sure the oil level indicator tube is positioned behind the EGR cooler coolant supply tube before installing the EGR cooler coolant supply tube.

Position a new clamp and install the EGR cooler coolant supply tube and bolts.
- Tighten to 13 Nm (115 lb-in).
Tighten the clamp for the EGR cooler coolant supply hose.
- Tighten to 4 Nm (35 lb-in).
Connect the anti-lock module electrical connector.

Fig 5: Locating Anti-Lock Module Electrical Connector
Courtesy of FORD MOTOR CO.

NOTE: Install a new O-ring seal on the oil level tube prior to installing.

Position the oil level indicator tube. Install the bolt.
- Tighten to 13 Nm (115 lb-in).
Install the nut for the oil level indicator tube. Install the oil level indicator.
- Tighten to 31 Nm (23 lb-ft).
Install the LH fender splash shield. For additional information, refer to FRONT END BODY PANELS .
Install the LH front wheel and tire. Carry out the Wheel and Tire - Single Rear Wheel (SRW) or the Wheel and Tire - Dual Rear Wheels (DRW) procedure. For additional information, refer to WHEELS AND TIRES .
Install the degas bottle. For additional information, refer to ENGINE COOLING .
Install the LH turbocharger inlet pipe. For additional information, refer to EXHAUST SYSTEM .