Ford Freestar, Monterey 2004-2006

Exhaust Manifold

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Removal & Installation



Left Side Exhaust Manifold

NOTE
Spray the exhaust system fasteners with penetrating lubricant before removing them to help prevent broken studs and bolts. The use of a 6-point socket is highly recommended when removing exhaust system fasteners.


CAUTION
To prevent serious burns, allow the exhaust manifold to cool down before attempting to remove it.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the dipstick tube bolt.
  4.  
  5. Disconnect the EGR tube from the manifold.
  6.  
  7. Raise and support the vehicle safely on jackstands.
  8.  
  9. Disconnect the dual converter Y-pipe from the exhaust manifold.
  10.  
  11. Lower the vehicle.
  12.  
  13. Remove the exhaust manifold.
  14.  

To install:

Click image to see an enlarged view

Fig. Left side exhaust manifold tightening sequence-3.9L and 4.2L engines

  1. Clean all gasket mating surfaces thoroughly.
  2.  
  3. Install a new exhaust manifold gasket and the exhaust manifold on the cylinder head. Start 2 nuts to hold the manifold in position.
  4.  
  5. Install the remaining nuts. Tighten the nuts in the sequence shown to 18 ft. lbs. (25 Nm).
  6.  
  7. Raise and support the vehicle safely.
  8.  
  9. Connect the dual converter Y-pipe.
  10.  
  11. Lower the vehicle.
  12.  
  13. Install the EGR tube.
  14.  
  15. Install the dipstick bolt.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Start the engine and check for exhaust leaks.
  20.  

 
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