Lincoln F5AZ-9430-A Exhaust Manifold Assembly

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Disconnect the battery cable from the negative terminal of the battery. Raise the vehicle and support it securely on jackstands. Working under the vehicle, apply penetrating oil to the exhaust pipe-to-manifold studs and nuts. Remove the nuts that hold the exhaust pipe flange to the exhaust manifold. Unplug the electrical connector for the oxygen sensor. Lower the vehicle and remove the spark plug heat shields, if equipped. First, remove the spark plug heat shield nuts and then remove the shield, and spark plugs. Remove the manifold heat shields, if equipped. On some models, it is necessary to remove the heat shield nuts and the heat shield to gain access to the exhaust manifold bolts - use penetrating oil to make the fasteners easier to remove. Remove the air cleaner assembly and heat stove tube, if equipped. For the right side manifold, remove the Thermactor hardware, if equipped. Remove the automatic transmission fluid dipstick tube, if necessary. For the left side manifold, if it's in the way, remove the engine oil dipstick and tube. For both manifolds, bend back the locking tabs. Some models are equipped with manifold bolt locking tabs -bend these down before removing the bolts - use new locking assemblies on installation, bending the tabs up to lock the bolts in place, if equipped. Remove the mounting bolts and separate the manifold from the head. Use a deep socket to remove the special stud bolts used to retain the spark plug heat shield. Note the locations of the pilot bolts.Check the manifold for cracks and make sure the bolt threads are clean and undamaged. The manifold and cylinder head mating surfaces must be clean before the manifolds are reinstalled - use a gasket scraper to remove all carbon deposits and old gasket material. Position the manifold and gasket, if used, on the head and install the mounting bolts. When tightening the mounting bolts, work from the center to the ends and tighten the bolts in three equal steps. The remaining installation steps are the reverse of removal. Start the engine and check for exhaust leaks.

To remove the exhaust manifold first unplug the battery and then take the vehicle off the ground on jack stands. Soak the exhaust pipe to manifold studs and nuts with penetrating oil because they are usually severely rusted; then, undo the nuts fastening the exhaust pipe(s) to the manifold(s). If more force is required to break the nuts loose, the nuts can be heated using propane or acetylene torch. Remove the EGR tube connector from the right side manifold and two through bolts of engine mount. Slowly raise the engine with a floor jack to avoid stretching hoses and connections and with great care for the bulk of the wiper module, cooling fan and fuel lines. Should it be necessary, disconnect the lower engine mount on the left side to allow access to all bolts that are used to attach the exhaust manifold to the cylinder head The exhaust manifold(s) bolts to cylinder head(s) are then removed in order to separate the manifold from the cylinder head. For reassembly, inspect the manifold for cracks and be sure that the bolt threads are dry and both have no damage then clean the mating surfaces before replacing. Place the manifold on the head and fit the mounting bolts and as is always recommended use the torque wrench in steps to tighten the bolts from the center and ends. Last of all, turn on the engine and look for signs of exhaust.

Disconnect the cable from the negative terminal of the battery and unplug the electrical connector for the oxygen sensor. Remove the spark plug heat shields, if equipped, and the spark plugs. Raise the vehicle and support it securely on jackstands. While working under the vehicle, apply penetrating oil to the exhaust pipe-to-manifold studs and nuts, allowing the fluid to sit for as long as possible to loosen rusty parts. Remove the air cleaner assembly and heat stove tube, if equipped. For the right side manifold, take out the Thermactor hardware, if equipped, and the automatic transmission fluid dipstick tube if necessary, along with the exhaust manifold heat shield, if equipped. For the left side manifold, remove the engine oil dipstick and tube if it obstructs access. Bend back the locking tabs, if equipped, then remove the mounting bolts and separate the manifold from the head, noting the locations of the pilot bolts. Check the manifold for cracks and ensure the bolt threads are clean and undamaged, making sure the mating surfaces are clean before reinstalling. Position the manifold and gasket on the head and install the mounting bolts, tightening them from the center to the ends using a torque wrench in three equal steps until the specified torque is reached. Complete the remaining installation steps in reverse order of removal, then start the engine and check for exhaust leaks.

The manifold and cylinder head mating surfaces must be clean before the manifolds are reinstalled.

Remove the Thermactor hardware, if equipped.

Position the manifold on the head and install the mounting bolts.