Exhaust Manifold Replacing Procedure for Ford, Mercury and Lincoln?

The procedure is similar for Ford Crown Victoria, Mercury Grand Marquis, Lincoln Town Car.          

Exhaust Manifold

REMOVAL & INSTALLATION Details are follows.

Follow the instructions mentioned below:-----

Left Side

Specific to:

Ford Crown Victoria 2008-2009

Lincoln Town Car 2008-2009

Mercury Grand Marquis 2008-2009

1. If equipped with a fire suppression system, depower the system.
2. Disconnect the negative battery cable.
3. With the vehicle in NEUTRAL, position it on a hoist.
   
   NOTE

   Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
4. Using a suitable holding device, hold the steering wheel in the straight-ahead position
   
   NOTE

   Do not allow the intermediate shaft to rotate while it is disconnected from the steering gear or damage to the clockspring may result. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered.
5. Remove the intermediated shaft pinch bolt and detach the intermediate shaft from the steering gear and position aside.
6. Remove the 2 exhaust manifold heat shield bolts and the shield.
7. Remove the 2 catalytic converter-to-exhaust manifold nuts and position aside the catalytic converter flange. Discard the nuts.
8. Disconnect the EGR system module tube from the exhaust manifold.
9. Remove the LH Heated Oxygen Sensor (HO2S).
10. Remove the 8 nuts, the exhaust manifold and the gasket. Discard the nuts and gasket.
11. Remove and discard the 8 exhaust manifold studs.
12. Clean and inspect the exhaust manifold for flatness. 
    
    
    
    Fig. View of the left exhaust manifold (1 Of 2)
    
    
    
    

    

    Fig. View of the left exhaust manifold (2 Of 2)

To install:

1. Install the 8 new exhaust manifold studs. Tighten to 106 inch lbs. (12 Nm).
2. Install a new exhaust manifold gasket, the exhaust manifold and 8 new nuts. Tighten in sequence shown to 15 ft. lbs. (20 Nm).
3. Install the LH HO2S .
4. Connect the EGR system module tube to the exhaust manifold. Tighten to 32 ft. lbs. (43 Nm).
5. Position the catalytic converter flange and install the new catalytic converter-to-exhaust manifold nuts. Tighten to 35 ft. lbs. (48 Nm).
6. Install the exhaust manifold heat shield and the 2 bolts. Tighten to 89 inch lbs. (10 Nm).
7. Position the intermediate shaft on the steering gear and install the pinch bolt. Tighten to 22 ft. lbs. (30 Nm).
8. Connect the battery ground cable.
9. If equipped with a fire suppression system, repower the system.
   
   
   

   

   Fig. Left exhaust manifold tightening sequence

Right Side

Specific to:

Ford Crown Victoria 2008-2009

Lincoln Town Car 2008-2009

Mercury Grand Marquis 2008-2009

1. If equipped with a fire suppression system, depower the system.
2. Drain the engine cooling system.
3. Disconnect the negative battery cable.
4. Rotate the drive belt tensioner clockwise and remove the drive belt.
5. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
6. Disconnect the A/C compressor electrical connector.
7. Remove the bolt from the transmission cooler tube bracket.
8. Remove the nut and position aside the transmission cooler tube assembly.
9. Remove the 3 bolts and position aside the A/C compressor.
10. Remove the catalytic converter-to-exhaust manifold nuts and position aside the catalytic converter flange. Discard the nuts.
11. Remove the 8 nuts, the exhaust manifold and the gasket. Discard the nuts and gasket.
12. Remove and discard the 8 exhaust manifold studs.
13. Clean and inspect the exhaust manifold for flatness.
    
    
    

    

    Fig. Components to be removed for the right exhaust manifold (1 Of 2)
    
    
    
    

    

    Fig. View of the right exhaust manifold (2 Of 2)

To install:

1. Install the 8 new exhaust manifold studs. Tighten to 106 inch lbs. (12 Nm).
2. Install a new exhaust manifold gasket, the exhaust manifold and 8 new nuts. Tighten in sequence shown to 15 ft. lbs. (20 Nm).
3. Position the catalytic converter flange and install the new catalytic converter-to-exhaust manifold nuts. Tighten to 35 ft. lbs. (48 Nm).
4. Position the A/C compressor and install the 3 bolts. Tighten to 18 ft. lbs. (25 Nm).
5. Position the transmission cooler tube assembly and install the nut. To install, tighten to 80 inch lbs. (9 Nm).
6. Install the transmission cooler tube bracket bolt. To install, tighten to 133 inch lbs. (15 Nm).
7. Connect the A/C compressor electrical connector.
8. Connect the CKP sensor electrical connector.
9. Rotate the drive belt tensioner clockwise and install the drive belt.
10. Connect the battery ground cable.
11. If equipped with a fire suppression system, repower the system.
    
    
    

    

    Fig. Right exhaust manifold tightening sequence

This details will help.

Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html