Ford XL1Z-9431-BA
Exhaust Manifold, Driver Side

A technician should start the right-hand exhaust manifold service by disconnecting the battery ground cable before lifting and supporting the vehicle. Take out the two nuts from the Y pipe while lowering the vehicle partially. Start by removing the right front wheel combined with its tire before proceeding to eliminate the right front fender splash shield. First disconnect the starter cable harness bolt before setting the cable out of the way. Begin by removing eight nuts from the exhaust manifold before taking out the manifold together with its gasket. Perform the opposite steps of removal while applying fresh gasket material before securing the exhaust manifold bolts in a particular order.

The first step to service the exhaust manifold on the left-hand side requires vehicle lift and position support. The maintenance of the Y-pipe requires removing its two nuts next you should partially lower the raised vehicle. The service begins with tire wheel removal from the left front and continued with removal of the left front splash shield. Before uninstalling the exhaust manifold you must disconnect the EGR to exhaust manifold tube components while removing its eight mounting nuts. Remove both the exhaust manifold along with its attached gasket after nut removal. Complete installation requires the reversal of removal steps while also including a new gasket.

Install the EGR valve-to-exhaust manifold tube, reconnect the differential pressure feedback EGR sensor and its electrical connector, and tighten both fittings in two stages: hand-tighten first, then tighten to 35 - 45 Nm (26 - 33 ft. lbs.). Install the brake booster vacuum hose, bracket, and nut.

Connect the EGR valve to exhaust manifold tube upper fitting, tightening both fittings in two stages: first hand-tighten, then tighten to 40 Nm (30 ft. lbs.).

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

Raise and support the vehicle.

Remove the right-hand front fender splash shield.

Reverse the removal steps and ensure to install a new gasket.

Remove the two nuts from the Y-pipe.