Ford F81Z-9430-AA Exhaust Manifold Assembly

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EGR system vehicles feature a left exhaust manifold that can be removed by first disconnecting the EGR valve tube fitting on the manifold before disconnecting the actual tube. To start with, exhaust air intake duct for V10 engines must be retractable completely. Start by lifting the car on jack stands, for V8 cars, take of the left front wheel while for the V10 cars take off the right front wheel. Further, it is possible to take off the front inner fenderwell if necessary. Pertaining to 2003 through 2004 2-valve models, support the vehicle securely and, if working on a 4X4, retract the suitable wheel well opening. Dependent on models, either take out the front fender inner splash shields or for engine models 6.8L take out the air filter outlet tube for convenient clearance into the left manifold. On 2003 models powered by 6.8L engines, it is recommended that the EGR tube be disconnected at the left manifold. On 2005 and later 3-valve models, before performing the procedure, the air filter housing and all the interfering ducts connect to it must be removed; this does not apply to the right-side manifolds of 6.8L engines. For 4X4 models with 5.4L engines the front driveshaft require to be taken off and if right side manifold is to be removed the starter should be also taken off. On 6.8L models, the transmission filler tube will have to be removed to get to the right-side manifold and to replace left-side manifold, then unbolt the coolant degas reservoir. Take out the front fender inner splash shields; the exhaust pipe-to-exhaust manifold stud and nuts should be treated with a penetrating oil because they usually seize. Take off the nuts that connect the exhaust pipe to the exhaust manifold, followed by the eight or ten nuts of the exhaust manifold and then take off the exhaust manifold with the old gaskets. Scrape off all the previous gasket materials from the cylinder head and exhaust manifold so that there is no dirty compound before it is put back. Check the exhaust manifold for cracks; if present, then the exhaust manifold may have to be either changed or fixed or an estimate has to be taken from an automotive machine shop. Check the threads of the exhaust manifold studs and make sure they are not damaged and use thread chaser if they are damaged and replace the studs. New gaskets should fitted, exhaust manifold must be located properly and nuts tightened in the sequence according to the torque. Before tightening the EGR tube back to the left manifold, which is also tightened with a screw, it is advisable to put a little of anti-seize compound on the threads. Last, the process is the removal process a bit in reverse and after starting the engine, look for exhaust smoke.

Remove the eight exhaust manifold bolts.