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Exhaust Manifold: Removal

WARNING: This page is about a different car, the 2007 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
  2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  3. Remove the accessory drive belt. For additional information, refer to ACCESSORY DRIVE article.
  4. Drain the engine cooling system. For additional information, refer to ENGINE COOLING article.
  5. Remove the 2 exhaust downpipe flange nuts.
  6. Disconnect the upper radiator hose and the degas bottle coolant hose from the front coolant outlet pipe.
  7. If equipped, remove the A/C compressor. For additional information, refer to CLIMATE CONTROL article.
  8. Disconnect the heater coolant hose from the front coolant outlet pipe.
  9. Remove the oil level indicator, the 2 bolts and the oil level indicator tube.
    • Discard the O-ring seal.
  10. Remove the 2 bolts and the front coolant outlet pipe.
    Fig 1: Locating Bolts & Front Coolant Outlet Pipe
    GF0008954Courtesy of FORD MOTOR CO.
    • Discard the O-ring seal.
  11. Remove the pushpins and position the right inner fender splash shield aside.
  12. Disconnect the generator electrical connections.
  13. Remove the 5 bolts and the generator and support bracket assembly.
  14. Remove the 2 nuts and position the coolant tube aside.
  15. Remove the 7 nuts, the exhaust manifold, the gasket and the studs.
    • Discard the exhaust manifold nuts and the gasket.
  16. Remove and discard the exhaust manifold-to-cylinder head studs.
  17. Clean and inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
    18. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.
  18. Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging. Observe all warnings and cautions and follow all application directions contained on the packaging of the metal surface prep.
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