Continental 2000-2002

Exhaust Manifold

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Removal & Installation




NOTE
Disable the air suspension before raising the vehicle. The switch is located on the left side of the luggage compartment.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Turn the air suspension switch to the OFF position.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Radiator splash shield
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Dual converter Y-pipe
     
    Exhaust Gas Recirculation (EGR) tube
     
    Secondary air injection tubes
     
    Exhaust manifolds
     

  6.  

To install:

  1. Install or connect the following:

    Exhaust manifolds. Tighten the nuts in sequence to 13-16 ft. lbs. (18-22 Nm).
     
    Secondary air injection tubes. Tighten the nuts to 25-34 ft. lbs. (34-46 Nm).
     
    EGR tube. Tighten the nut to 30-33 ft. lbs. (40-45 Nm).
     
    Dual converter Y-pipe
     
    HO 2 S sensor connectors
     
    Radiator splash shield
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Exhaust manifold torque sequence-right side shown, left side similar

     

  2.  
  3. Turn the air suspension switch to the ON position.
  4.  
  5. Start the engine and check for leaks.
  6.  

3.8L Engine
Left Side
  1. Disconnect the negative battery cable.
  2.  



Click image to see an enlarged view

Fig. Remove the nut holding the dipstick tube support bracketand the stud. Matchmark the stud and hole

  1. Remove the oil level dipstick tube support bracket.
  2.  



Click image to see an enlarged view

Fig. Remove the bolts and studs to the exhaust manifold

  1. Tag and disconnect the spark plug wires.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the exhaust manifold-to-exhaust pipe attaching nuts.
  6.  



Click image to see an enlarged view

Fig. Usually soaking the exhaust nuts with a rust solvent . . .



Click image to see an enlarged view

Fig. . . . makes them easier to remove. There is one on each side of the pipe. You will need a flex joint to remove them

  1. Lower the vehicle.
  2.  
  3. Remove the exhaust manifold retaining bolts, then remove the exhaust manifold from the vehicle.
  4.  



Click image to see an enlarged view

Fig. Left side exhaust manifold mounting-3.8L engine

To install:

  1. Lightly oil all bolt and stud threads before installation. Clean the exhaust manifold, cylinder head and Y-pipe mating surfaces.
  2.  
  3. Position the exhaust manifold on the cylinder head. Install the lower front bolt on the No. 5 cylinder as a pilot bolt.
  4.  


NOTE
A slight warping in the exhaust manifold may cause a misalignment between the boltholes in the head and the manifold. Elongate the holes in the exhaust manifold as necessary to correct the misalignment, if apparent. Do not elongate the pilot hole, the lower front bolt on No. 5 cylinder.

  1. Install the remaining exhaust manifold retaining bolts, then tighten the bolts 15-22 ft. lbs. (20-30 Nm).
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Connect the dual converter Y-pipe to the exhaust manifold. Tighten the attaching nuts to 16-24 ft. lbs. (21-32 Nm).
  6.  
  7. Carefully lower the vehicle.
  8.  
  9. Connect the spark plug wires as tagged during removal.
  10.  
  11. Install the oil level dipstick tube support bracket-attaching nut. Tighten to 15-22 ft. lbs. (20-30 Nm).
  12.  
  13. Connect the negative battery cable, then start the engine, and check for exhaust leaks.
  14.  

Right Side
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner and the air cleaner outlet tube assembly.
  4.  
  5. Tag and disconnect the ignition wire from the ignition coil, then tag and disconnect the wires from the spark plugs. Remove the spark plugs.
  6.  
  7. Disconnect the EGR valve-to-exhaust manifold tube.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Remove the transaxle dipstick tube.
  12.  
  13. Remove the exhaust manifold-to-exhaust pipe attaching nuts.
  14.  
  15. Carefully lower the vehicle.
  16.  
  17. Remove the exhaust manifold retaining bolts, them remove the exhaust manifold from the vehicle.
  18.  



Click image to see an enlarged view

Fig. Right side exhaust manifold mounting-3.8L engine

To install:

  1. Lightly oil all bolt and stud threads before installation. Clean the exhaust manifold, cylinder head and Y-pipe mating surfaces.
  2.  
  3. Position the inner half of the heat shroud, if equipped, and exhaust manifold on cylinder head. Start two retaining bolts to align the manifold with the cylinder head. Install the remaining retaining bolts and tighten to 15-22 ft. lbs. (20-30 Nm). Do not overtorque the retainers, it may cause exhaust leaks.
  4.  


NOTE
A slight warping in the exhaust manifold may cause a misalignment between the boltholes in the cylinder head and exhaust manifold. Elongate the holes in the exhaust manifold as necessary to correct the misalignment. Do not elongate the pilot hole (the lower rear bolt hole on the No. 2 cylinder).

  1. Raise and safely support the vehicle.
  2.  
  3. Connect the dual converter Y-pipe to the exhaust manifold. Tighten the retaining nuts to 16-24 ft. lbs. (22-33 Nm).
  4.  
  5. Install the transaxle dipstick tube, and then carefully lower the vehicle.
  6.  
  7. If equipped, install the outer heat shroud, then tighten the retaining screws to 50-70 inch lbs. (6-8 Nm).
  8.  
  9. Install the spark plugs. Connect the ignition wires to their respective spark plugs, then connect the ignition wire to the coil.
  10.  
  11. Apply special heat-resistant anti-seize compound to the threads and connect the EGR valve-to-exhaust manifold tube.
  12.  
  13. Install the air cleaner. Install the air cleaner outlet tube assembly.
  14.  
  15. Connect the negative battery cable, then start the engine, and check for exhaust leaks. Check the transaxle fluid.
  16.  

4.6L Engine
Left Side
  1. Disable the air suspension.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and safely support the vehicle securely on a hoist.
  6.  
  7. Remove the splash shield form the lower radiator support and the front sub-frame.
  8.  
  9. Remove the dual converter Y pipe.
  10.  
  11. Loosen the retaining nut and remove the LH secondary air injection manifold tube from the LH exhaust manifold.
  12.  
  13. Remove the eight exhaust manifold-to-cylinder head retaining nuts.
  14.  
  15. remove the LH exhaust manifold and exhaust manifold gaskets.
  16.  

To install:

  1. Clean the mating surfaces of the exhaust manifold and the cylinder head.
  2.  
  3. Install the new exhaust manifold gasket on the LH cylinder head. Lightly press the exhaust manifold gasket over the exhaust manifold-positioning studs.
  4.  
  5. Install the LH exhaust manifold and install the eight retaining nuts. Tighten the retaining nuts in sequence to 13-16 ft. lbs. (18-22 Nm)
  6.  
  7. Connect the LH secondary air injection manifold tube to the LH exhaust manifold. Tighten the nut for the LH secondary air injection manifold tube to the LH exhaust manifold to 25-34 ft. lbs. (34-46Nm)
  8.  
  9. Install the dual converter Y pipe.
  10.  
  11. Install the splash shield to front sub-frame and lower radiator support. Tighten the retaining screws securely.
  12.  
  13. Lower the vehicle and connect the negative battery cable.
  14.  
  15. Check the exhaust system for leaks. Turn on the air suspension
  16.  

Right Side
  1. Disable the air suspension.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and safely support the vehicle securely on a hoist.
  6.  
  7. Disconnect the heated oxygen sensors at the wiring connectors.
  8.  
  9. Remove the dual converter Y pipe.
  10.  
  11. Remove the exhaust connector retaining bolts and exhaust connector and muffler inlet pipe gasket from the RH exhaust manifold
  12.  
  13. Remove the EGR valve to exhaust manifold tube from the EGR valve tube to manifold connector using a 22 mm crowfoot wrench.
  14.  
  15. Loosen the retaining nut and remove the RH secondary air injection manifold tube from the RH exhaust manifold.
  16.  
  17. Remove the eight exhaust manifold-to-cylinder head retaining nuts.
  18.  
  19. Remove the RH exhaust manifold from the RH cylinder head by gaining access through the RH wheel opening area.
  20.  
  21. Remove the exhaust manifold gasket from the RH cylinder head Discard the exhaust manifold gasket.
  22.  

To install:

  1. Clean the mating surfaces of exhaust manifold and cylinder head.
  2.  
  3. If removed, install the EGR valve tube to manifold connector to the RH exhaust manifold. Tighten the EGR valve tube to manifold connector to 33-48 ft. lbs.. (45-65 Nm)
  4.  
  5. Position the new exhaust manifold gasket and the exhaust manifold onto the cylinder head. Install the eight retaining nuts. Tighten in sequence to 13-16 ft. lbs. (18-22 Nm)
  6.  
  7. Connect the RH secondary air injection manifold tube to the RH exhaust manifold. Tighten the nut for the RH secondary air injection manifold tube to the RH exhaust manifold to 25-34 ft. lbs.(34-46 Nm)
  8.  
  9. Connect the EGR valve to exhaust manifold tube to the EGR valve to exhaust manifold tube to the EGR valve tube to manifold connector. Tighten the nut to 30-33 ft. lbs. (40-45 Nm)
  10.  
  11. Install the exhaust connector with a new muffler inlet-pipe-gasket and retaining bolts to the RH exhaust manifold. Tighten the retaining bolts in two steps.
    1. Tighten the bolts in sequence to 13-17 ft. lbs. (17-23 Nm).
    2.  
    3. Tighten the bolts in sequence to 30-40 ft. lbs. (41-54 Nm)
    4.  

  12.  
  13. Install the dual converter Y pipe, and connect the heated oxygen sensors the wiring harness connectors.
  14.  
  15. Lower the vehicle and connect the negative battery cable.
  16.  
  17. Check the exhaust system for leaks. Turn on the air suspension.
  18.  

 
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