RH Exhaust Manifold: Installation

All vehicles 

1. NOTE: 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. Use a plastic scraper to clean the sealing surfaces.

   Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.

2. Install 8 new RH exhaust manifold studs.
   • Tighten to 25 Nm (18 lb-ft).
3. Install new gaskets, the RH exhaust manifold and 8 new nuts.
   • Tighten nuts in the sequence shown in illustration in 2 stages.
     • Stage 1: Tighten to 24 Nm (18 lb-ft).
     • Stage 2: Tighten to 32 Nm (24 lb-ft).
       Fig 1: Identifying RH Exhaust Manifold Nuts Tightening Sequence

       Courtesy of FORD MOTOR CO.
4. NOTE: The engine support insulator bracket must be positioned on the engine support insulator stud. If necessary, adjust the height of the engine using the engine support bar.

   Install the RH engine support insulator bracket, the 2 bolts and the 2 stud bolts.

   • Tighten to 55 Nm (41 lb-ft).
     Fig 2: Locating RH Engine Support Insulator Bracket, Bolts And Stud Bolts

     Courtesy of FORD MOTOR CO.
5. Install the ground strap and the nut to the RH engine support insulator bracket.
   • Tighten to 48 Nm (35 lb-ft).
     Fig 3: Locating RH Engine Support Insulator Bracket Nut And Ground Strap

     Courtesy of FORD MOTOR CO.
6. Attach the wiring harness retainers to the RH side of the oil pan and the RH engine support insulator bracket stud bolt.
   Fig 4: Locating Wiring Harness Retainers

   Courtesy of FORD MOTOR CO.
7. Install the transmission cooler tube clamp and nut to the RH engine support insulator bracket.
   • Tighten to 48 Nm (35 lb-ft).
     Fig 5: Locating RH Engine Support Insulator Bracket And Nut

     Courtesy of FORD MOTOR CO.
8. Install the transmission fluid cooler tube bracket and nut to the flexplate inspection cover stud bolt.
   • Tighten to 13 Nm (115 lb-in).
     Fig 6: Locating Transmission Fluid Cooler Tube Bracket And Nut

     Courtesy of FORD MOTOR CO.
9. Position the underbody shield and install the 3 bolts.
   • Tighten to 10 Nm (89 lb-in).
10. Install the starter. For additional information, refer to STARTING SYSTEM .
11. Install the RH catalytic converter. For additional information, refer to EXHAUST SYSTEM .
12. Install the front crossmember brace and the 4 nuts (2 shown in illustration).
    • Tighten to 48 Nm (35 lb-ft).
13. Using the Engine Support Bar, lower the engine onto the engine support insulators.
14. NOTE: RH shown in illustration, LH similar.

    Install the RH and LH engine support insulator nuts.

    • Tighten to 63 Nm (46 lb-ft).
      Fig 7: Locating Engine Support Insulator Nut

      Courtesy of FORD MOTOR CO.
15. Connect the RH HO2S electrical connector.
    Fig 8: Locating RH Heated Oxygen Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
16. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
17. Using a new O-ring seal and gasket seal, connect the A/C compressor fitting and install the nut
    • Tighten to 15 Nm (133 lb-in).
      Fig 9: Locating A/C Compressor Fitting And Nut

      Courtesy of FORD MOTOR CO.
18. Position the sound enhancement pipe and install the bolt.
    • Tighten to 8 Nm (71 lb-in).

    Boss® 302 vehicles 

19. Attach the wiring harness retainer and the hood release cable retainer to the radiator support.

    All vehicles 

20. Install the upper radiator sight shield and the 8 pin-type retainers.
    Fig 10: Locating Upper Radiator Sight Shield And Pin-Type Retainers

    Courtesy of FORD MOTOR CO.
21. NOTE: The engine appearance cover rubber grommets may remain on the cover. If so, remove the grommets from the cover and install them on the intake manifold before installing the cover.

    If equipped, install the engine appearance cover.

    Fig 11: Locating Engine Appearance Cover

    Courtesy of FORD MOTOR CO.
22. NOTE: Base 5.0L (4V) vehicle shown in illustration, Boss® 302 similar.

    If equipped, install the strut tower cross brace and the 4 nuts.

    • Tighten to 35 Nm (26 lb-ft).
      Fig 12: Locating Strut Tower Cross Brace And Nuts

      Courtesy of FORD MOTOR CO.
23. Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .