Ford 7E5Z-5G232-A
Exhaust Manifold

The first step to service the right-hand exhaust manifold on an all-wheel drive vehicle requires positioning the vehicle at neutral on a hoist. Start the procedure by uninstalling the EGR tube along with the right-hand catalytic converter. The power steering rack heat shield needs removal before the heat shield from the exhaust manifold because removing the power steering rack heat shield bolts makes it possible to take off the catalytic converter heat shield. After taking out six nuts, remove the right-hand exhaust manifold from the engine bay while throwing away both items plus their corresponding gasket and nuts. The six right-hand catalytic converter studs should also be taken out and disposed. Start with new six right-hand catalytic converter studs before tightening each one to 12 Nm (9 ft. lbs.). Install the power steering rack heat shield within the engine compartment after positioning the catalytic converter heat shield while tightening its two bolts to 15 Nm (11 ft. lbs.). Place a new gasket together with the right-hand exhaust manifold and six new nuts at specified torque of 20 Nm (15 ft. lbs.) while following the sequence. The right-hand catalytic converter along with the EGR tube need to be reinstalled last.

A suitable solvent should be used for exhaust manifold cleaning before applying a plastic scraping tool to clean the gasket sealing surfaces. A new replacement of exhaust manifold gaskets with corresponding installation of studs and nuts and bolts is essential during this maintenance work. Your repair process should include the use of the Snap-On(R) GA438A Straightedge which the manufacturer has manufactured to exhibit flatness with 0.005 mm (0.0002 in) precision per one running foot of length. The machined edge of the Straightedge measuring 61 cm (24 in) requires its flatness to be maintained at 0.010 mm (0.0004 in) across its complete 24 in length. The service requires a new exhaust manifold if the Feeler Gauge Set reveals warpage exceeding 0.76 mm (0.0299 in) on the exhaust manifold sealing surface after preparing the Straightedge.