Ford 7L1Z-9431-A
Exhaust Manifold, Driver Side

The replacement process for the left-hand exhaust manifold needs to start with placing the vehicle into neutral gear and positioning it on a hoist. Start the engine replacement by disconnecting the air cleaner outlet pipe together with the degas bottle. The intermediate shaft disconnect process requires caution because steering column shaft rotation could damage the Clock Spring. In case the column does rotate, the technician needs to remove and realign the Clock Spring. Initially disconnect the steering shaft by removing its bolt and place it safely to the side. Minimize the four exhaust manifold-to-catalytic converter nuts before proceeding to remove the front driveshaft from four-wheel drive models. The eight exhaust manifold nuts and eight studs need removal along with the exhaust manifold from the engine bay before discarding both components. Use a plastic scraper together with metal surface prep to clean the sealing surfaces while preventing damage from abrasive tools. Take out the two exhaust manifold gaskets while inspecting the exhaust manifold structure. Use new exhaust manifold gaskets together with eight new studs before spacing them correctly and tightening them to 12 Nm (106 lb-in). The installation process requires new exhaust manifold nuts which should be tightened to 25 Nm (18 lb-ft) as per the specific sequence established for the work. Front driveshaft reinstallation becomes necessary for vehicles having four-wheel drive. The steering shaft receives installation first with the bolt secured at 30 Nm (22 lb-ft). Then install the four exhaust manifold-to-catalytic converter nuts and finally attach the degas bottle and air cleaner outlet tube.

All vehicles need their exhaust manifold serviced by first being positioned in the NEUTRAL gear on a hoist. The service process begins with removing the front wheel opening molding in addition to the front fender splash shield when working with 4x4 vehicles. The Romeo engine service requires the removal of a brake booster vacuum hose nut along with its bracket before disconnecting differential pressure feedback EGR sensor tubes from an EGR valve tube and removing exhaust manifold connection to EGR valve tube. Installments for the Windsor engine (5.4L) include removing the bolt followed by brake booster vacuum hose and bracket detachment then disconnecting the differential pressure feedback EGR system hoses and the upper and lower exhaust manifold to EGR valve tube fittings. The process begins by taking out the nuts and exhaust manifold while wasting the exhaust manifold gasket before cleaning and checking the exhaust manifold. The new exhaust manifold gasket needs to be positioned first with exhaust manifold installation taking place second before fully tightening nuts according to their required sequence. Attach the three-way catalytic converter to manifold nuts. The installation of the exhaust manifold-to-EGR valve tube requires hand tightening of the fittings before proceeding to tighten both upper and lower fittings. The differential pressure feedback EGR sensor hoses should connect to the EGR valve tube followed by installation of the brake booster vacuum hose along with its bracket and tightener. Windsor engine owners should replicate the installation of exhaust manifold-to-EGR valve tube followed by attaching brake booster vacuum hose and its bracket with bolt. As the last step replace the front fender splash shield followed by installation of the front wheel opening moldings for 4x4 vehicles.

Inspect the exhaust manifold for any damage.

Remove the right-hand inner fenderwell and the right-hand engine support insulator.

Install a new exhaust manifold gasket.

Remove the nuts securing the three-way catalytic converter to the exhaust manifold.

Disconnect the left-hand H02S electrical connector.

Discard both the nuts and the gasket, along with the six left-hand exhaust manifold studs.

Remove and discard the old exhaust manifold gaskets and inspect the exhaust manifold for any damage.

A new exhaust manifold gasket.

Reinstall it and tighten the nuts to 25 Nm (18 lb-ft).

Remove the four bolts and lower the sway bar.

Remove the starter and the right-hand inner fender well.

Reinstall the front driveshaft.

Remove the right-hand exhaust manifold and discard the gaskets.

Reinstall the front driveshaft.

Remove the two nuts securing the engine lifting eye.

Ensure the vehicle is in neutral and positioned on a hoist.