Replacement
REMOVAL1. Disconnect battery ground cable (14301).
2. Remove air cleaner outlet tube (9B659).
3. Drain cooling system and remove fan blade (8600) and fan shroud (8146). Refer to Cooling System.
4. Relieve fuel system pressure and disconnect fuel lines. Refer to Powertrain Management.
5. Remove upper radiator hose (8260).
6. Remove windshield wiper governor (17C476) and support bracket.
7. Recover air conditioning system. Refer to Heating and Air Conditioning.
8. Disconnect A/C compressor to condenser discharge line (19972) at A/C compressor (19703) and remove nut retaining hose to engine front cover stud bolt.
9. Disconnect 42-pin connector and eight-pin transmission harness connector at power brake booster (2005).
10. Disconnect heater water hose (18472). Remove if necessary.
11. Remove nut retaining ground strap to RH cylinder head (6049).
12. Remove heater blower motor switch resistor (18591).
13. Remove bolt retaining RH front engine support insulator (6038) to front sub-frame (5C145).
14. Disconnect both heated oxygen sensors (HO2S)(9F472).
15. Raise and support vehicle.
16. Remove oil bypass filter (6714).
NOTE: Two through-bolts are required for LH front engine support insulator and one through-bolt is required for RH front engine support insulator.
17. Remove front engine support insulator through-bolts.
18. Remove EGR valve to exhaust manifold tube nut from RH exhaust manifold (9430).
19. Disconnect three way catalytic converter (TWC)(5E212) from RH and LH exhaust manifolds.
20. Lower exhaust and secure to crossmember in positions shown with wire.
21. For LH exhaust manifold, remove front engine support insulator from cylinder block (6010) and remove eight nuts retaining exhaust manifold.
22. Remove LH exhaust manifold and two exhaust manifold gaskets (9448).
23. Position a screw-type jackstand and a block of wood under oil pan (6675), rearward of oil drain hole.
24. Raise engine approximately 100 mm (4 inches).
25. For RH exhaust manifold, remove eight nuts retaining exhaust manifold to cylinder head and retaining studs and remove exhaust manifold and exhaust manifold gasket.
INSTALLATION
1. If exhaust manifolds are being replaced, transfer heated oxygen sensors and tighten to 37-45 Nm (28-33 ft. lbs.). Also, for RH exhaust manifold, transfer EGR valve tube to manifold connector (9F485) and tighten to 45-65 Nm (34-48 ft. lbs.).
2. Clean mating surfaces of exhaust manifolds and cylinder heads.
3. Position exhaust manifold gasket and RH exhaust manifold to cylinder head and studs and install eight retaining nuts. Tighten in sequence to 18-22 Nm (14-16 ft. lbs.).
4. Position two exhaust manifold gaskets and LH exhaust manifold to cylinder head and studs and install eight retaining nuts. Tighten in sequence to 18-22 Nm (14-16 ft. lbs.).
5. Position and connect EGR valve to exhaust manifold tube (9D477) to exhaust manifold. Tighten line nut to 35-45 Nm (26-33 ft. lbs.).
6. Install LH front engine support insulator on cylinder block and tighten bolts to 20-30 Nm (15-22 ft. lbs.).
7. Lower engine onto front engine support insulator and remove jack.
NOTE: Two through-bolts are required on LH front engine support insulator and one through-bolt is required on RH front engine-support insulator.
8. Install front engine support insulator through bolts and tighten to 20-30 Nm (15-22 ft. lbs.).
NOTE: Make sure exhaust system clears No.3 crossmember. Adjust as necessary.
9. Remove wire and position three way catalytic converter. Install four nuts and tighten to 27-41 Nm (20-30 ft. lbs.).
10. Install oil bypass filter.
11. Lower vehicle.
12. Connect fuel charging wiring (9D930) to both heated oxygen sensors.
13. Install bolt retaining RH from it engine support insulator to front sub-frame. Tighten to 20-30 Nm (15-22 ft. lbs.).
14. Install heater blower motor switch resistor with two retaining screws.
15. Install ground strap onto stud and tighten nut to 20-30 Nm (15-22 ft. lbs.).
16. Connect heater water hose. If removed, install and tighten fasteners to 20-30 Nm (15-22 ft. lbs.).
17. Connect fuel charging wiring to 42-pin engine harness connector and eight-pin transmission harness connector at power brake booster.
18. Connect A/C compressor to condenser discharge line to A/C compressor and install nut retaining hose to engine front cover stud bolt.
19. Install upper radiator hose.
20. Connect fuel lines. Refer to Powertrain Management.
21. Install windshield wiper governor and retaining bracket.
22. Evacuate and recharge air conditioning system. Refer to Heating and Air Conditioning.
23. Install fan blade and fan shroud. Fill and bleed cooling system. Refer to Cooling System.
24. Connect battery ground cable.
25. Install air cleaner outlet tube.
26. Check and add clean engine oil meeting Ford specification WSS-M2C910-A1.
27. Start engine and check for leaks.