Ford 2L1Z-9430-BA Exhaust Manifold Assembly

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The first step in removing the exhaust manifold, is to reduce the pressure in the fuel system for 6.2L or, discharge the A/C system on the 5.0L. Remove the negative battery terminal, properly support the car on jack stands and then remove the inner splash shield of the fenderwell. Pour penetrating oil on the studs and nuts of the exhaust pipe to manifold, and on the 4.6L engines, put penetrating oil also on EGA pipe fitting. Pull the EGR pipe out of its positions on the EGR valve and exhaust manifold and unbolt the exhaust Y-pipe or dual-catalyst Y-pipe nuts. In the case of car models containing engines using 3-valves, one has to unscrew the heat shield bolts in addition to the heat shield, and the eight kulak breathe nuts on the exhaust manifold. Move on to the next step, which is to take of the exhaust manifold and also the old gasket. They are the starter, nuts of the Y-pipe, and at times the drive belt for the right exhaust manifold where you have to reverse the above process. On the 5.4L engine, it is necessary to remove the heated oxygen sensors, the Y-pipe support bracket and the air intake duct if it is to be removed and the nuts and heat shield from the catalytic converter. For the 6.2L engine, support the engine from above, remove the nuts from the catalytic converter bracket, loosen the transmission-to-crossmember nuts, then, remove the nuts from the engine mount. This is done by first removing all old exhaust manifold studs and then ascertaining that the exhaust manifolds are free from cracks; clean the mating surfaces, put a new gasket and finally tightening the mounting nuts in an orderly manner. Last but not the least; connect back the EGR pipe using anti-seize compound and check whether there is any exhaust leak after starting the engine and charge the AC if necessary.

Remove the nut holding the oil dipstick tube support at the front of the manifold, then pull the dipstick tube up and out of the oil pan.

Remove the eight mounting nuts from each manifold.

Start the engine and check for exhaust leaks.

Position the exhaust manifold and new gasket over the studs on the cylinder head and install the mounting nuts.