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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 - RH >> Removal

Exhaust Manifold - RH: 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.

All vehicles 

  1. Remove the Air Cleaner (ACL) assembly. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  2. Remove the auxiliary air intake tube.
    Fig 1: Locating Auxiliary Air Intake Tube
    G06763174Courtesy of FORD MOTOR CO.

    Vehicles with A/C 

  3. Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .

    All vehicles 

    NOTE: Position a suitable material in front of the Charge Air Cooler (CAC) or damage to the CAC  may occur.
  4. Disconnect the battery ground cables. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  5. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  6. Remove the 2 exhaust downpipe-to-Oxidation Catalytic Converter (OC) pipe bolts.
    Fig 2: Locating Exhaust Downpipe-To-Oxidation Catalytic Converter Pipe Bolts
    G06778518Courtesy of FORD MOTOR CO.
  7. Remove and discard the exhaust downpipe clamp. Position aside the exhaust downpipe.
    • Remove and discard the exhaust downpipe gasket.
      Fig 3: Locating Exhaust Downpipe Clamp
      G06778104Courtesy of FORD MOTOR CO.
  8. Disconnect the Exhaust Pressure (EP) sensor tube from the EGR- OC  pipe.
    Fig 4: Locating Exhaust Pressure Sensor Tube
    G06763073Courtesy of FORD MOTOR CO.
  9. Remove the EGR- OC  pipe bracket-to-bracket bolt and washer. Remove the bracket-to-cylinder head bolt, washers and the bracket.
    • Discard the bolts.
      Fig 5: Locating EGR-OC Pipe Bracket-To-Bracket Bolt And Washer
      G06763074Courtesy of FORD MOTOR CO.
  10. Remove the 2 EGR- OC  -to-EGR cooler bolts.
    • Discard the bolts and gasket.
      Fig 6: Locating EGR-OC-To-EGR Cooler Bolts
      G06778172Courtesy of FORD MOTOR CO.
  11. Remove the 2 EGR- OC  pipe bolts and the 2 EGR- OC  -to-turbocharger bracket bolts.
    • Position the EGR- OC  pipe aside.
    • Discard the bolts and gasket.
      Fig 7: Locating EGR-OC Pipe Bolts And EGR-OC-To-Turbocharger Bracket Bolts
      G06763082Courtesy of FORD MOTOR CO.
  12. Remove 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 .
  13. Remove the RH fender splash shield. For additional information, refer to FRONT END BODY PANELS .
  14. Remove the Exhaust Gas Recirculation Temperature (EGRT) sensor from the RH turbocharger inlet pipe.
    Fig 8: Locating Exhaust Gas Recirculation Temperature Sensor
    G06778167Courtesy of FORD MOTOR CO.
  15. Remove and discard the 3 RH turbocharger inlet pipe-to-exhaust manifold nuts.
    Fig 9: Locating RH Turbocharger Inlet Pipe-To-Exhaust Manifold Nuts
    G06777927Courtesy of FORD MOTOR CO.
  16. Remove the 3 RH turbocharger inlet pipe-to-exhaust manifold studs.
    • Discard the studs.
      Fig 10: Locating RH Turbocharger Inlet Pipe-To-Exhaust Manifold Studs
      G06778178Courtesy of FORD MOTOR CO.
  17. Remove the 3 RH turbocharger inlet pipe bolts.
    • Position the RH turbocharger inlet pipe aside.
    • Discard the bolts and gasket.
      Fig 11: Locating RH Turbocharger Inlet Pipe Bolts
      G06777926Courtesy of FORD MOTOR CO.
  18. Remove the nut and position the battery cable bracket aside.
    Fig 12: Locating Battery Cable Bracket Nut
    G06774306Courtesy of FORD MOTOR CO.
  19. Remove the cover for the starter terminals.
    Fig 13: Locating Starter Terminals Cover
    G06774307Courtesy of FORD MOTOR CO.
  20. Remove the 2 retaining nuts for the starter solenoid wiring. Position the starter wiring aside.
    Fig 14: Locating Retaining Nuts And Starter Solenoid Wiring
    G06774308Courtesy of FORD MOTOR CO.

    Vehicles with A/C 

  21. Disconnect the A/C compressor wire retainer. Position the wiring aside.
    Fig 15: Locating A/C Compressor Wire Retainer
    G06774309Courtesy of FORD MOTOR CO.
  22. Remove the 2 nuts and position aside the A/C hoses.
    • Discard the O-ring seal and gaskets.
    • Plug or cap the openings.
      Fig 16: Locating A/C Hoses Nuts
      G06774310Courtesy of FORD MOTOR CO.

    Vehicles with automatic transmission 

  23. Remove the retaining nut and position the transmission fluid indicator tube off the stud.
    Fig 17: Locating Transmission Fluid Indicator Tube Off Stud Retaining Nut
    G06774311Courtesy of FORD MOTOR CO.

    All vehicles 

  24. 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 with the specifications.
  25. Remove the 3 bolts and nut for the heat shield. Remove the heat shield.
  26. Remove the 3 spacers from the exhaust manifold stud bolts.
    27. NOTE: Mark the location of the fasteners prior to removing.
  27. Remove the 4 stud bolts and 4 bolts. Remove the exhaust manifold and exhaust manifold gasket.
    • Discard the gasket, stud bolts and bolts.
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