Exhaust Manifold - RH: 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.
All vehicles
- Position a new exhaust manifold gasket and the exhaust manifold. Install the 4 new stud bolts and the 4 new bolts. Tighten 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).
- Install the 3 spacers on the exhaust manifold stud bolts.
- Tighten to 19 Nm (168 lb-in).
- Position the exhaust manifold heat shield. Install the nut and 3 bolts.
- Tighten to 19 Nm (168 lb-in).
Vehicles with automatic transmission
- Position back the transmission fluid level indicator tube and install the nut.
- Tighten to 8 Nm (71 lb-in).
Vehicles with A/C
- Install the A/C hoses and 2 nuts.
- Tighten to 15 Nm (133 lb-in).
- Position back and connect the A/C compressor wire retainer.
All vehicles
- Position back the starter wiring. Install the 2 retaining nuts for the starter solenoid wiring.
- Tighten the large nut to 12 Nm (106 lb-in) and the small nut to 6 Nm (53 lb-in).
- Install the cover for the starter terminals.
- Position back the battery cable bracket and install the nut.
- Tighten to 25 Nm (18 lb-ft).
- Position back the RH turbocharger inlet pipe. Install a new gasket and the 3 new RH turbocharger inlet pipe-to-exhaust manifold studs.
- Tighten to 18 Nm (159 lb-in).
- Install a new turbocharger inlet pipe gasket and loosely install the 3 new RH turbocharger inlet pipe bolts.
- Tighten the top 2 bolts to 25 Nm (18 lb-ft).
- A 3/8-in drive torque wrench that is 241.3 mm (9.5 in) or 368.3 mm (14.5 in) from center of the handle to the center of the square drive.
- One of the 10-mm/12-mm Half-moon wrenches listed in the following chart.
- A 12-mm Allen socket (to drive the Half-moon wrench).
- Tighten the RH turbocharger inlet pipes-to-turbocharger bottom bolt.
- Refer to the following chart for torque wrench setting, based on the specific Half-moon wrench and torque wrench length being used.
Courtesy of FORD MOTOR CO.
TORQUE CHART - TURBOCHARGER INLET PIPES-TO-TURBOCHARGER, BOTTOM 2 BOLTSHalf-Moon Wrench Brand Wrench Part Number Wrench Size Torque Wrench Length Torque Wrench setting Nm lb-in Cornwell® BWM-1012MM 10/12mm 9.5 in 20 177 Gear Wrench® 9851 10/12mm 9.5 in 18 159 Matco® MHM1012 10/12mm 9.5 in 18 159 Mac® HMM1012R 10/12mm 9.5 in 15 133 Snap-On® CXM1012 10/12mm 9.5 in 18 159 Cornwell® BWM-1012MM 10/12mm 14.5 in 19 168 Gear Wrench® 9851 10/12mm 14.5 in 18 159 Matco® MHM1012 10/12mm 14.5 in 18 159 Mac® HMM1012R 10/12mm 14.5 in 10 142 Snap-On® CXM1012 10/12mm 14.5 in 18 159 NOTE: To achieve the required torque of 25 Nm (18 lb-in), the torque wrench must be set to the appropriate Torque Wrench Setting listed in this chart.
- Refer to the following chart for torque wrench setting, based on the specific Half-moon wrench and torque wrench length being used.
- Position the 2 EGR- OC pipe and loosely install the 2 new bracket bolts. Install a new gasket and loosely install the 2 new bolts.
- Install the 3 new RH turbocharger inlet pipe-to-exhaust manifold nuts.
- Tighten to 31 Nm (23 lb-ft).
- Install the EGRT
sensor into the RH turbocharger inlet pipe.
- Tighten to 44 Nm (32 lb-ft).
- Install the RH fender splash shield. For additional information, refer to FRONT END BODY PANELS .
- Install the RH front tire and wheel. Carry out Wheel and Tire - Single Rear Wheel (SRW) or Wheel and Tire - Dual Rear Wheels (DRW). For additional information, refer to WHEELS AND TIRES .
- Install the bracket, washers and loosely install the 2 new bolts for the EGR- OC pipe bracket.
- Install the new gasket and the 2 new bolts for the EGR cooler.
- Tighten to 31 Nm (23 lb-ft).
- Tighten the 2 EGR- OC
pipe bolts at the RH turbocharger inlet pipe.
- Tighten to 31 Nm (23 lb-ft).
- Tighten the 2 bolts for the EGR- OC
pipe bracket at the turbocharger.
- Tighten to 31 Nm (23 lb-ft).
- Install a new gasket and loosely install the new clamp for the exhaust downpipe.
- Align the new exhaust downpipe-to-turbocharger clamp so that the exhaust downpipe clip and the opening in the exhaust downpipe-to-turbocharger clamp are aligned and tighten to maintain position.
- Align the downpipe so that the area just above the flat in the pipe is approximately 20 mm (0.787 in) from the frame.
- Tighten the bolt for the EGR- OC
pipe bracket.
- Tighten to 31 Nm (23 lb-ft).
- A 3/8-in drive torque wrench that is 368.3 mm (14.5 in) or 381.0 mm (15.0 in) from the center of the handle to the center of the square drive.
- One of the 11-mm/13-mm Half-moon wrenches listed in the following chart.
- A 11-mm Allen socket (to drive the Half-moon wrench).
- Tighten the EGR- OC
pipe bracket-to-LH cylinder head bolt.
- Refer to the following chart for torque wrench setting, based on the specific Half-moon wrench and torque wrench length being used.TORQUE CHART - OC - EGR PIPE BRACKET-TO-LH CYLINDER HEAD BOLT
Half-Moon Wrench Brand Wrench Part Number Wrench Size Torque Wrench Length Torque Wrench setting Nm lb-ft Cornwell® BWM-1113MM 11/13mm 14.5 in 48 35 Gear Wrench® 9852 11/13mm 14.5 in 46 34 Matco® MHM1113 11/13mm 14.5 in 43 04 Mac® HMM1113R 11/13mm 14.5 in 46 34 Snap-On® CXM1113 11/13mm 14.5 in 46 34 Cornwell® BWM-1113MM 11/13mm 15.0 in 49 36 Gear Wrench® 9852 11/13mm 15.0 in 49 36 Matco® MHM1113 11/13mm 15.0 in 48 35 Mac® HMM1113R 11/13mm 15.0 in 48 35 Snap-On® CXM1113 11/13mm 15.0 in 48 35 NOTE: To achieve the required torque of 63 Nm (16 lb-ft), the torque wrench must be set to the appropriate Torque Wrench Setting listed in this chart.
- Refer to the following chart for torque wrench setting, based on the specific Half-moon wrench and torque wrench length being used.
- Connect the EP
sensor tube to the EGR- OC
pipe.
- Tighten to 20 Nm (177 lb-in).
- Install the 2 exhaust downpipe-to- OC
pipe bolts.
- Tighten to 40 Nm (30 lb-ft).
- Tighten the clamp for the exhaust downpipe.
- Tighten to 15 Nm (133 lb-in).
- Connect the battery ground cables. For additional information, refer to
BATTERY, MOUNTING AND CABLES
.
Vehicles with A/C
- Evacuate and charge the A/C system. For additional information, refer to
CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS
.
All vehicles
- Position the auxiliary air intake hose in the vehicle.
- Install the ACL assembly. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
NOTE:
Install a new O-ring seal and gasket.
NOTE:
Due to limited access, one of the specific Half-moon wrenches and other tools described must be used to correctly tighten the fasteners in this step. Failure to follow this instruction may result in engine failure.
NOTE:
To complete this step, it will be necessary to use the following tools:
NOTE:
To obtain the required torque value of 25 Nm (18 lb-ft), it will be crucial to orient the Half-moon wrench in the direction shown in the illustration and 180 degrees (straight out) from the torque wrench. The torque wrench must be set to the value specified in the following chart, for the Half-moon wrench and torque wrench length being used.
NOTE:
Make sure the correct bolts are installed in the bracket or damage to the bracket can occur.
NOTE:
Failure to install and correctly tighten the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) pipe support bolts will result in damage to the horizontal EGR cooler and possible engine damage.
NOTE:
Failure to install and correctly tighten the Exhaust Gas Recirculation (EGR)- OC
pipe support bolt will result in damage to the horizontal EGR cooler and possible engine damage.
NOTE:
Failure to install and correctly tighten the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) pipe support bolt will result in damage to the horizontal EGR cooler and possible engine damage.
NOTE:
Due to limited access, one of the specific Half-moon wrenches and other tools described must be used to correctly tighten the fasteners in this step. Failure to follow this instruction may result in engine failure.
NOTE:
To complete this step, it will be necessary to use the following tools:
NOTE:
To obtain the required torque value of 63 Nm (46 lb-ft), it will be crucial to orient the Half-moon wrench in the direction shown in the illustration and 180 degrees (straight out) from the torque wrench. The torque wrench must be set to the value specified in the following chart, for the Half-moon wrench and torque wrench length being used.