Ford XL3Z-9430-GA
Exhaust Manifold, Passenger Side

Starting the exhaust manifold service and repair requires hoisting the vehicle with neutral transmission and removing the engine cover. Service of the Romeo engine's EGR valve tube requires disconnecting sensor hoses from the device and removing the tube by unplugging its upper and lower fittings. Repeat the EGR valve tube disconnection process and tube removal procedure that applies to Windsor engines. The procedure starts with removing the front fender splash shield and moving onto the exhaust manifold nuts before taking off the manifold itself. Dispose of the old gasket. Regular inspection should involve cleaning the exhaust manifold prior to installation. Install the new exhaust manifold gasket followed by fitting the exhaust manifold with loose nuts that need installation according to sequence. Secure the three-way catalytic converter by screwing it to the exhaust manifold nuts. Install the Windsor EGR valve fittings through two steps: do a hand-tightening procedure and torque the bottom fitting to 50 Nm (37 ft. lbs.). Connect both EGR sensor hoses through the differential pressure feedback to the EGR valve tube. You should install the EGR valve tube for Romeo engines by first connecting and hand-tightening both fittings before torquing up to 40 Nm (30 ft-lbs). The differential feedback EGR sensor hoses should be connected to the EGR valve tube before reinstalling the front fender splash shield along with the engine cover.

Before reaching the right-hand exhaust manifold for servicing you must start by disconnecting the battery ground cable then supporting the vehicle. Remove first the two Y pipe nuts and lower the vehicle partially. The right front wheel and tire assembly needs removal before proceeding to remove the right front fender splash shield. Remove the harness bolt that secures the starter cable before placing the cable to the side. The eight nuts on the exhaust manifold need to be removed before taking out the exhaust manifold together with the gasket. Install new gaskets when you install the system while performing the removal process in reverse order.

Also take out the gasket.

Begin by removing the oil level indicator extension and the oil level indicator tube.

Install the EGR valve-to-exhaust manifold tube, tightening the upper and lower fittings in two stages: hand-tighten first, then tighten the lower fitting to 50 Nm (37 ft. lbs.).

Detach the exhaust manifold-to-EGR valve tube and disconnect the right Heated Oxygen Sensor (H02S) electrical connector.

Clean and inspect the exhaust manifold.

Install a new exhaust manifold gasket.

Ensure to tighten the bolts in the specified sequence, reversing the removal procedure.

Disconnect the battery ground cable.

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

Remove the oil level indicator extension and the oil level indicator tube, discarding the O-ring.

Remove and discard the eight exhaust manifold-to-cylinder head studs, and clean and inspect the exhaust manifold.

Lower the vehicle and then take off the exhaust manifold along with its nuts, discarding the exhaust manifold gaskets.

Remove the LH exhaust manifold along with the LH exhaust manifold gasket by taking out the LH stud bolts and bolts, and discarding the gasket.

Reverse the removal procedure and ensure to tighten the exhaust manifold nuts in the specified sequence.

Remove and discard them, then clean and inspect the exhaust manifold.

Remove the LH exhaust manifold along with the LH exhaust manifold gasket by taking out the LH stud bolts and bolts, and discard the gasket.

Clean and inspect the exhaust manifold.

Disconnect the right-hand Heated Oxygen Sensor (H02S) electrical connector.

Raise and support the vehicle.

Disconnect the upper and lower fittings and remove the EGR system module-to-exhaust manifold tube.

Disconnect the upper and lower fittings and remove the exhaust gas recirculation (EGR) system module-to-exhaust manifold tube.

Yes, the procedure is similar for both engines.

Disconnect the electrical connector for the LH Heated Oxygen Sensor (HO2S) and remove the nuts to disconnect the Y-pipe from the LH exhaust manifold.

The nuts, the exhaust manifold, and the gasket, discarding the old gasket.

Remove the engine cover.

Remove the two nuts securing the engine lifting eye.

Remove the nuts and the exhaust manifold, discarding the exhaust manifold gasket. Clean and inspect the exhaust manifold before installation.

Position the brake booster vacuum hose bracket and install the nut, then reinstall the front fender splash shield and the front wheel opening molding for 4x4 vehicles before lowering the vehicle.

Tighten the nuts in the designated sequence.

Tighten the exhaust manifold nuts according to the specified sequence.

Raise and support the vehicle.

Disconnect the battery ground cable and raise the vehicle on a hoist.

Disconnect the EGR-to-exhaust manifold tube lower fitting.

Remove the nuts securing the manifold.

Reverse the removal steps.

Reinstall the front fender splash shield and the front wheel opening molding.

Disconnect the EGR-to-exhaust manifold tube lower fitting.

Remove the left front inner fender well.

Clean and inspect the exhaust manifold.

Remove the nuts securing the manifold.

Disconnect the battery ground cable.

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

Ensure to discard the old gasket.