How to replace Exhaust Manifold on ford E series Vans?

The details to replace exhaust Manifold on ford e series:----


Exhaust Manifold
REMOVAL & INSTALLATION procedure:----

4.6L, 5.4L & 6.8L Engines
Left Side

Specific to:

Ford E-150 2008-2009

Ford E-250 2008-2009

Ford E-350 Super Duty 2008-2009

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove the engine cover.
3. Disconnect the upper and lower fitting and remove the EGR system module-to-exhaust manifold tube, 4.6L engine only.
4. Remove the four exhaust Y-pipe flange nuts.
5. Remove and discard the nuts and the exhaust manifold.
6. Remove and discard the exhaust manifold gasket.
7. Remove and discard the exhaust manifold-to-cylinder head studs.

To install:

1. Install new exhaust manifold-to-cylinder head studs and tighten to 106 inch lbs. (12 Nm).
2. Using new exhaust manifold gaskets, position the exhaust manifold and tighten the new nuts in sequence as follows:
   
   
   4.6L engine: 15 ft. lbs. (20 Nm)

   5.4L & 6.8L engines: 18 ft. lbs. (25 Nm)
   
   

   

   

   Fig. Left exhaust manifold torque sequence-4.6L engine

   
   
   

   

   

   Fig. Left exhaust manifold torque sequence-5.4L engine

   
   
   

   

   

   Fig. Left exhaust manifold torque sequence-6.8L engine
3. Install the Y-pipe and tighten the new nuts to 30 ft. lbs. (40 Nm).
4. If equipped with 4.6L engine, install the EGR system module-to-exhaust manifold tube and tighten the upper and lower fittings in 2 stages:
   1. Connect the upper and lower fittings and hand-tighten.
   2. Tighten to 31 ft. lbs. (42 Nm).
5. Install the engine cover.

Right Side

Specific to:

Ford E-150 2008-2009

Ford E-250 2008-2009

Ford E-350 Super Duty 2008-2009

1. Before servicing the vehicle, refer to the Precautions Section.
2. Disconnect the negative battery cable.
3. Raise and safely support the vehicle.
4. Remove the four exhaust Y-pipe flange nuts.
5. Remove and discard the nuts and the exhaust manifold.
6. Remove the exhaust manifold and discard the gaskets.
7. Remove and discard the exhaust manifold-to-cylinder head studs.

To install:

1. Install new exhaust manifold-to-cylinder head studs and tighten to 106 inch lbs. (12 Nm).
2. Using new exhaust manifold gaskets, position the exhaust manifold and tighten the new nuts in sequence as follows:
   
   
   4.6L engine: 15 ft. lbs. (20 Nm)

   5.4L & 6.8L engine: 18 ft. lbs. (25 Nm)
   
   

   

   

   Fig. Right exhaust manifold torque sequence-4.6L engine

   
   
   

   

   

   Fig. Right exhaust manifold torque sequence-5.4L engine

   
   
   

   

   

   Fig. Right exhaust manifold torque sequence-6.8L engine
3. Install the Y-pipe and tighten the new nuts to 30 ft. lbs. (40 Nm).
4. Connect the negative battery cable.

6.0L Engine
Left Side

Specific to:

Ford E-150 2008-2009

Ford E-250 2008-2009

Ford E-350 Super Duty 2008-2009

1. Before servicing the vehicle, refer to the Precautions Section.
2. Raise and safely support the vehicle.
3. Remove the engine cover.
4. Remove the left bolts for the turbocharger adapter pipe.
5. Disconnect the exhaust back pressure tube.
6. Remove the bolts and the left exhaust manifold.

To install:

NOTE

Start installing the bolts with the second bolt from the rear on the top. The hole diameter is smaller, therefore allowing alignment of the remaining bolts.

NOTE

Apply anti-seize lubricant to the bolt threads prior to installing the bolts.

1. Install the left exhaust manifold with new spacers and new bolts. Tighten the bolts in the sequence shown to 28 ft. lbs. (38 Nm).
   
   
   

   

   Fig. Left exhaust manifold torque sequence-6.0L engine
2. Connect the exhaust back pressure tube at the exhaust manifold.
3. Install the left bolts for the turbocharger adapter pipe.
4. Install the engine cover.

Right Side

Specific to:

Ford E-150 2008-2009

Ford E-250 2008-2009

Ford E-350 Super Duty 2008-2009

1. Before servicing the vehicle, refer to the Precautions Section.
2. Raise and safely support the vehicle.
3. Disconnect the battery ground cable.
4. Remove the engine cover.
5. Remove the right bolts for the turbocharger adapter pipe.
6. Remove the bolts and the right exhaust manifold.

To install:

NOTE

Start installing the bolts with the second bolt from the rear on the top. The hole diameter is smaller, therefore allowing alignment of the remaining bolts.

NOTE

Apply anti-seize lubricant to the bolt threads prior to installing the bolts.

1. Install the right exhaust manifold with new spacers and new bolts. Tighten the bolts in the sequence shown to 28 ft. lbs. (38 Nm).
   
   
   

   

   Fig. Right exhaust manifold torque sequence-6.0L engine
2. Install the right bolts for the turbocharger adapter pipe.
3. Install the engine cover.
4. Connect the battery ground cable.

This details will help.

Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

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