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Home >> Ford >> 2003 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2471 (Engine Mechanical - 6.4L 99R Diesel -- F250-F550 Super Duty) >> In-Vehicle Repair >> Exhaust Manifold - LH >> Removal

Exhaust Manifold - LH: Removal

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.
  1. Remove the LH turbocharger inlet pipe. For additional information, refer to EXHAUST SYSTEM .
  2. Remove the degas bottle. For additional information, refer to ENGINE COOLING .
  3. Remove 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 .
  4. Remove the LH fender splash shield. For additional information, refer to FRONT END BODY PANELS .
  5. Remove the oil level indicator. Remove the nut for the oil level indicator tube.
  6. Remove the bolt and position the oil level indicator tube aside.
    • Remove and discard the O-ring seal.
  7. Disconnect the anti-lock module electrical connector and position aside.
    Fig 1: Locating Anti-Lock Module Electrical Connector
    G06774285Courtesy of FORD MOTOR CO.
  8. Loosen the clamp for the EGR cooler coolant supply hose.
    9. 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.
    NOTE: Position a drain pan prior to removing the EGR cooler coolant supply tube.
  9. Remove the bolts and the EGR cooler coolant supply tube.
    • Discard the clamp on the hose and the O-ring seal on the tube.
    10. 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.
  10. Loosen the clamp and disconnect the EGR cooler outlet coolant hose.
    • Discard the clamp.
  11. Remove the 2 nuts for the horizontal EGR cooler outlet.
  12. Remove the 2 studs for the horizontal EGR cooler outlet.
    • Remove and discard the gasket.
  13. Remove the bolt and disconnect the steering shaft.
    • Discard the bolt.
      Fig 2: Locating Steering Shaft Bolt
      G06780931Courtesy of FORD MOTOR CO.
  14. Remove the 2 nuts, separate the clamps and remove the horizontal EGR cooler.
    • Discard the nuts.
      Fig 3: Locating Nuts, Clamps And Horizontal EGR Cooler
      G06774287Courtesy of FORD MOTOR CO.
  15. Prior to removing the exhaust manifold, inspect the exhaust manifold for warpage with a feeler gauge between the manifold and the cylinder head. Record the measurement and compare to Specifications.
  16. Remove the 4 horizontal EGR cooler bracket bolts and the bracket.
    • Discard the bolts.
  17. Remove the 4 bolts, the exhaust manifold and the exhaust manifold gasket.
    • Discard the bolts and gasket.
  18. Remove the 2 pins from the back of the horizontal EGR cooler bracket. Remove and discard the EGR cooler clamps.
    Fig 4: Locating EGR Cooler Clamps Pins
    G06774288Courtesy of FORD MOTOR CO.
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