Ford 5S4Z-5G232-DA Exhaust Manifold Assembly

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To remove the intake manifold on models through 2004, follow these steps:1. Depressurize the fuel system and disconnect the negative battery cable.2. Remove the air cleaner and inlet duct, and disconnect the accelerator cable.3. For 2.3L and 2005 and later 2.0L models, remove the engine cooling fan and shroud.4. Disconnect the brake booster vacuum hose from the base of the manifold and remove the engine oil dipstick and its tube.5. Disconnect the injection harness wiring plug and camshaft position sensor at the rear of the cylinder head.6. Disconnect all electrical connectors from the throttle body.7. For models through 2004, disconnect the fuel supply and return lines from the fuel rail, protecting the alternator from fuel spillage.8. If equipped, disconnect the intake manifold runner control (IMRC) cable.9. Remove the manifold support bracket (SPI engines) and manifold retaining bolts.10. Withdraw the manifold from the engine, keeping it as level as possible, and recover the four gaskets (new ones must be used on installation).

A sulphurous smell from the exhaust may be noticed, which is more related to the sulfur content of the fuel than the converter itself.

A new gasket will be sufficient to ensure the joint is gas-tight. Do not use any kind of exhaust sealant upstream of the catalytic converter.

Be very careful when using the scraper, as the cylinder head is made of aluminum, which can easily be scratched or gouged. Aerosol gasket removal solvents may also be helpful.