Mercury 5M6Z-5G232-A Exhaust Manifold Assembly

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In the year 2008 and the models before it, start by jacking up the vehicle and putting it on the jackstands. Later, it is time to remove the exhaust pipe, as well as the catalytic converter, and, of course, the old flange gasket. Finally, remove the dipstick tube bracket bolt, pull the assembly up out of the engine compartment. Disconnect the electrical connection of the oxygen sensor and take off the device from the exhaust manifold. Subsequently, remove the exhaust manifold heat shield through the use of its bolts that should be unscrewed. Continue with the exhaust manifold bolts then the exhaust manifold and the old manifold gasket as well. Look at the exhaust manifold with special attention to any crack or damage and if there is, then it must be replaced. Wire brush clean all threads of the exhaust maniffold bolts and check for damaging , and replace those damaged ones. All gasket material has to be scraped off the mating surfaces and the surfaces have to be inspected for wear or cracks without damaging the aluminum surfaces. Check the flatness of the exhaust manifold contacting surfaces using a straightedge and a feeler gauge and if the distortion is more than that prescribed, the manifold or cylinder head should be replaced or machined. Apply anti-seize to the threads of the exhaust manifold bolts and studs, and then put on a new gasket and manifold, overtightening the fasteners in a star pattern and in increments to the suggested torque setting. The process of installation is Viv oppose to removal and after starting the engine, tap on the exhaust system for blows. For 2009 and later models when performing the following operations, use jackstands to lift the vehicle: Take off the front exhaust pipe from the exhaust manifold as well as the intermediate exhaust pipe. Remove the wiring harness from the oxygen sensor and, also, remove the exhaust manifold heat shield. Two samples of exhaust manifold mounting nuts should be removed and the ones used for the exercise must be discarded and replaced with new ones as there is no requirement for reusing them The exhaust manifold and its gasket should also be removed and the gasket must also be discarded. Bolt and nut the exhaust manifold mounting studs, check the manifold and refit it, if required, by having it machine flat. Replace the studs for the exhaust manifold and tighten the nuts on those studs as per manufactures recommended torque settings. Position a fresh gasket above the studs, fit on the manifold together with new nuts and then in a sequence-center first and then go outward-tighten nuts incrementally until you reach the outer nut and then loosen all the nuts a bit and then tighten the nuts in the same sequence again. The rest of the installation is simply the reversal of the removal procedure and do not forget to tighten the nuts holding the catalytic converter to the required torque before tightening the converter bracket bolts.

In the year 2008 and the models before it, start by jacking up the vehicle and putting it on the jackstands. Later, it is time to remove the exhaust pipe, as well as the catalytic converter, and, of course, the old flange gasket. Finally, remove the dipstick tube bracket bolt, pull the assembly up out of the engine compartment. Disconnect the electrical connection of the oxygen sensor and take off the device from the exhaust manifold. Subsequently, remove the exhaust manifold heat shield through the use of its bolts that should be unscrewed. Continue with the exhaust manifold bolts then the exhaust manifold and the old manifold gasket as well. Look at the exhaust manifold with special attention to any crack or damage and if there is, then it must be replaced. Wire brush clean all threads of the exhaust maniffold bolts and check for damaging , and replace those damaged ones. All gasket material has to be scraped off the mating surfaces and the surfaces have to be inspected for wear or cracks without damaging the aluminum surfaces. Check the flatness of the exhaust manifold contacting surfaces using a straightedge and a feeler gauge and if the distortion is more than that prescribed, the manifold or cylinder head should be replaced or machined. Apply anti-seize to the threads of the exhaust manifold bolts and studs, and then put on a new gasket and manifold, overtightening the fasteners in a star pattern and in increments to the suggested torque setting. The process of installation is Viv oppose to removal and after starting the engine, tap on the exhaust system for blows. For 2009 and later models when performing the following operations, use jackstands to lift the vehicle: Take off the front exhaust pipe from the exhaust manifold as well as the intermediate exhaust pipe. Remove the wiring harness from the oxygen sensor and, also, remove the exhaust manifold heat shield. Two samples of exhaust manifold mounting nuts should be removed and the ones used for the exercise must be discarded and replaced with new ones as there is no requirement for reusing them The exhaust manifold and its gasket should also be removed and the gasket must also be discarded. Bolt and nut the exhaust manifold mounting studs, check the manifold and refit it, if required, by having it machine flat. Replace the studs for the exhaust manifold and tighten the nuts on those studs as per manufactures recommended torque settings. Position a fresh gasket above the studs, fit on the manifold together with new nuts and then in a sequence-center first and then go outward-tighten nuts incrementally until you reach the outer nut and then loosen all the nuts a bit and then tighten the nuts in the same sequence again. The rest of the installation is simply the reversal of the removal procedure and do not forget to tighten the nuts holding the catalytic converter to the required torque before tightening the converter bracket bolts.

A catalytic converter (or catalyst) is an emission control device in the exhaust system that reduces certain pollutants in the exhaust gas stream. There are two types of converters: an oxidation catalyst, which reduces hydrocarbons (HC) and carbon monoxide (CO), and a reduction catalyst, which reduces oxides of nitrogen (NOx). Catalysts that can reduce all three pollutants are known as "three-way catalysts." The models covered by this manual are equipped with three-way catalysts.

The remainder of the installation is the reverse of the removal procedure.

a) Connect a vacuum gauge to an intake manifold vacuum source. b) Warm the engine to operating temperature, place the transaxle in Park (automatic models) or Neutral (manual models), and apply the parking brake. c) Note the vacuum reading at idle and jot it down. d) Quickly open the throttle to near its wide-open position and then quickly get off the throttle and allow it to close. Note the vacuum reading and jot it down. e) Repeat this test three more times, recording your measurement after each test. f) If your fourth reading is more than one in-Hg lower than the reading noted at idle, the exhaust system might be restricted, indicating that the catalytic converter could be plugged, or an exhaust pipe or muffler could be restricted.

Detach the EGR fitting nut.