Removing the exhaust manifold

Withdrawal

All engines except Zetec and Zetec-E

Remove the negative terminal from the battery.

The exhaust manifold is attached to the cylinder head with studs and nuts. The hot air intake is bolted to the exhaust manifold. To access the exhaust manifold mounting nuts, it is necessary to remove the heated air intake (see fig. 4E.7-4E.9).







On vehicles equipped with an air pulsation system, remove the air pulsation pipe. If there is an oxygen sensor, disconnect the connector and remove the sensor.


Support the exhaust pipe with a jack or suitable supports and unscrew the nuts securing the exhaust pipe to the manifold. Disconnect the pipe from the manifold and remove the gasket. Unscrew nuts of fastening and remove a collector from hairpins of a head of the block of cylinders. Remove the manifold gasket (see fig. 4E.10, 4E.11).

Zetec and Zetec-E engines

Remove the negative terminal from the battery. Remove the air supply pipes to the engine. Drain the coolant from the cooling system. Disconnect the coolant supply hoses to the thermostat housing.

Unscrew the bolt securing the heated air intake from the exhaust manifold and remove it (see fig. 4E.12).



Unscrew the bolt on the air filter housing and disconnect the vacuum hose of the air pulsation system or completely remove this system (see fig. 4E.13).




Disconnect the connector from the oxygen sensor wire. Unscrew nuts and disconnect a reception exhaust pipe from a collector.

Unscrew the nuts and remove the exhaust manifold with gasket (see fig. 4E.14).



Always use a new gasket when installing the exhaust manifold.

Examination

Using a scraper, remove the remnants of the old gasket and carbon deposits from the manifold and cylinder head.

On some models, the exhaust pipe is attached to the exhaust manifold with two coil spring bolts and a self-locking nut. When installing, tighten the nuts until they are seated on the bolt shoulders. In this case, the pressure of the spring will ensure the tightness of the connection (see fig. 4E.15-4E.17).

Installation

Installation is carried out in the reverse order of removal, taking into account the following points:

• install a new exhaust manifold gasket on the cylinder head studs and on Zetec and Zetec-E engines, install a new plastic guide bushing on the stud closest to the thermostat housing to properly seat the manifold. Do not install manifold without this bushing (see fig. 4E.18);
• install the manifold and screw on the fastening nuts;
• working from the middle in 3-4 steps, tighten the manifold fastening nuts to the required torque;
• install the remaining parts in the reverse order of removal;
• if necessary, add coolant to the cooling system;
• start the engine and check the exhaust system for leaks.