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    Ford Full-Size Vans 1989-1996 Repair Guide

    Exhaust Manifold

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    REMOVAL & INSTALLATION



    4.9L Engine

    The intake and exhaust manifolds on these engines are sometimes known as "combination manifolds" and are serviced as a unit. Typically, these manifolds are not referred to as a combination manifold, but since the lower intake and exhaust manifolds share the same bolts, and removal of either one requires removal of the other, we will refer to them as such. Refer to the Combination Manifold Removal & Installation procedure later in this section.

    5.0L and 5.8L Engines
    1989-94 MODELS

    See Figures 1, 2, 3, 4, 5, 6, 7 and 8

    1. Remove the air cleaner and the intake duct assembly, including the crankcase ventilation hose.
    2.  
    3. Loosen the air inlet duct retainers, if equipped.
    4.  
    5. Disconnect the muffler inlet pipes.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 1: Exploded view of exhaust manifold and heat shield assembly-1989-94 5.0L and 5.8L engines

    1. Loosen the manifold heat shield retainers and remove the shields, if so equipped.
    2.  
    3. If equipped, remove the air injection system lines.
    4.  
    5. On the left-hand manifold, remove the oil tube assembly, speed control bracket and, if equipped, the exhaust heat control valve.
    6.  
    7. Loosen the manifold retainers and remove the heat shield and manifold.
    8.  



    Click image to see an enlarged view

    Fig. Fig. 2: Loosen the air injection system lines at the manifold using flare nut and back-up wrenches



    Click image to see an enlarged view

    Fig. Fig. 3: Disconnect the lines from the exhaust manifold



    Click image to see an enlarged view

    Fig. Fig. 4: Remove the lines and set them aside



    Click image to see an enlarged view

    Fig. Fig. 5: Unfasten the exhaust manifold retainers



    Click image to see an enlarged view

    Fig. Fig. 6: Remove the heat shield from the manifold



    Click image to see an enlarged view

    Fig. Fig. 7: Separate the exhaust manifold from the engine ...



    Click image to see an enlarged view

    Fig. Fig. 8: ... and remove it from the engine compartment

    To install:
    1. Clean the manifold mating surfaces and cylinder head. Clean the exhaust pipe spherical seat on the manifold and the exhaust pipe sealing area.
    2.  
    3. Inspect the manifold for cracks and damaged gasket surfaces.
    4.  
    5. Install a new gasket and the manifold.
    6.  
    7. Install the oil dipstick tube.
    8.  
    9. Install the speed control bracket, if equipped.
    10.  
    11. Working from the center to the ends, tighten the bolts to 18-24 ft. lbs. (25-33 Nm).
    12.  
    13. Install new gaskets, if equipped on the muffler inlet pipe. Position the pipe and exhaust heat control valve (if equipped), into the manifolds. Install the retainers ands tighten them to 25-38 ft. lbs. (34-52 Nm).
    14.  
    15. Install the air cleaner and the duct assembly.
    16.  
    17. Install the crankcase ventilation hose.
    18.  

    1995-96 MODELS

    See Figure 9

    1. Raise the van and support it with safety stands.
    2.  
    3. Loosen the exhaust manifold-to-pipe nuts, then lower the van.
    4.  
    5. Remove the engine cover.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 9: Exhaust manifold and retainers-1995-96 5.0L and 5.8L engines

    1. Remove the right-hand exhaust manifold as follows:
      1. Remove the air cleaner assembly and outlet tube.
      2.  
      3. Loosen the retainers and disengage the upper intake support, transmission dipstick tube, engine oil, dipstick tube and wire brackets.
      4.  
      5. Loosen the nut securing the EGR tube to the exhaust manifold fitting.
      6.  
      7. Disengage the EGR valve connector.
      8.  
      9. Loosen the retainers and remove the EGR external pressure valve and EGR valve as an assembly.
      10.  
      11. Loosen the spark plug heat shield retainers and remove the shield.
      12.  

    2.  

    The exhaust manifold retainers vary in length and type both on the van and on the location. Keep track of what fasteners go where.

      1. Loosen the studs and bolts, then remove the exhaust manifold and gasket.
      2.  

    1. Remove the left-hand exhaust manifold as follows:
      1. On models with a C6 transmission, remove the secondary air injection manifold tube.
      2.  
      3. Loosen the lifting eye retainers and remove the eye.
      4.  
      5. Loosen the spark plug heat shield retainers and remove the heat shield.
      6.  
      7. Loosen the studs and bolts, then remove the exhaust manifold and gasket.
      8.  

    2.  

    To install:
    1. Clean the manifold mating surfaces and cylinder head. Clean the exhaust pipe spherical seat on the manifold and the exhaust pipe sealing area.
    2.  
    3. Inspect the manifold for cracks and damaged gasket surfaces.
    4.  
    5. Install the left-hand exhaust manifold as follows:
      1. Install a new gasket and the manifold.
      2.  
      3. Working from the center to the ends tighten the studs and the bolts to 18-24 ft. lbs. (24-32 Nm) on 1994-95 models and 26-32 ft. lbs. (35-43 Nm) on 1996 models.
      4.  
      5. Install the spark plug heat shields and tighten the retainers to 12-17 ft. lbs. (16-23 Nm).
      6.  
      7. Install the front lifting eye and tighten the retainers to 12-17 ft. lbs. (16-23 Nm).
      8.  
      9. On models with a C6 transmission, install the secondary air injection tube and tighten the retainers to 15-25 ft. lbs. (20-34 Nm) on 1994-95 models and 24-36 ft. lbs. (33-49 Nm) on 1996 models.
      10.  

    6.  
    7. Install the right-hand exhaust manifold as follows:
      1. Install a new gasket and the manifold.
      2.  
      3. Working from the center to the ends tighten the studs and the bolts to 18-24 ft. lbs. (24-32 Nm) on 1994-95 models and 26-32 ft. lbs. (35-43 Nm) on 1996 models.
      4.  
      5. Install the spark plug heat shields and tighten the retainers to 12-17 ft. lbs. (16-23 Nm).
      6.  
      7. Inspect the EGR valve-to-vent tube for damage or severely rusted and replace if necessary.
      8.  
      9. Install the EGR valve-to-exhaust manifold tube loosely to the manifold fitting.
      10.  
      11. Install a new gasket and the valve to the upper intake manifold studs. Tighten the EGR valve retainers to 13-19 ft. lbs. (18-26 Nm), then tighten the tube-to-exhaust manifold fitting nut to 25-35 ft. lbs. (34-47 Nm).
      12.  
      13. Install the wire, transmission tube, upper intake manifold support brackets and tighten the retainers to 12-18 ft. lbs. (16-24 Nm).
      14.  
      15. Install the air cleaner assembly and intake tube.
      16.  

    8.  
    9. Raise the van and support it with safety stands.
    10.  
    11. Install new exhaust pipe-to-manifold gaskets and the pipes. Tighten the retainers to 18-24 ft. lbs. (34-52 Nm) on 1994-95 models and 24-36 ft. lbs. (33-49 Nm) on 1996 models.
    12.  
    13. Lower the van and check for proper operation.
    14.  

    7.5L Engines

    See Figure 10

    1. If equipped, remove the spark plug heat shield retainers and heat shield.
    2.  
    3. Remove the spark plug wires.
    4.  
    5. If removing the left-hand manifold, disconnect the external EGR tube.
    6.  
    7. Disconnect the manifold at the muffler inlet pipe.
    8.  
    9. Remove the pump-to-exhaust manifold support brace from the back of the power steering pump.
    10.  
    11. If removing the left-hand manifold, remove the oil dipstick tube.
    12.  
    13. Loosen the bolts and washers, then remove the manifold.
    14.  
    15. Inspect the cylinder head joining flanges for evidence of exhaust leaks.
    16.  

    To install:
    1. Clean the manifold mating surfaces and cylinder head. Clean the mounting flange of the inlet pipes. Apply a light film of premium long life grease such as XG-1-C or -K or its equivalent to the exhaust manifold.
    2.  
    3. Inspect the manifold for cracks and damaged gasket surfaces.
    4.  
    5. Install a new gasket and the manifold.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 10: Exploded view of exhaust manifold and heat shield assembly-7.5L MFI engine

    1. Starting from the fourth bolt hole from the front of the manifold, tighten the studs and the bolts to 22-30 ft. lbs. (29-40 Nm) on 1989-93 models or 38-48 ft. lbs. (52-65 Nm) on 1994-96 models.
    2.  
    3. Engage the inlet pipe to the manifold and tighten the retainers to 25-38 ft. lbs. (34-52 Nm) on 1989-93 models or 25-36 ft. lbs. (39-49 Nm) on 1994-96 models.
    4.  
    5. If applicable, install the oil dipstick tube and connect the EGR tube.
    6.  
    7. Install the heat shield and spark plug wires.
    8.  
    9. Install the air cleaner and intake duct assemblies.
    10.  
    11. Start the engine and check for leaks.
    12.  

    7.3L Diesel Engine
    1989-94 MODELS

    See Figure 11

    1. Disconnect the negative battery cables.
    2.  
    3. If necessary, remove the radiator fan shroud.
    4.  
    5. If necessary, loosen the engine oil dipstick tube and transmission dipstick tube retainers and remove the tubes and dipsticks.
    6.  
    7. Raise the van and support it with safety stands.
    8.  
    9. Loosen the nuts retaining the right-hand engine mount to the frame, then slightly raise the right side of the engine until the fuel filter touches the sheet metal.
    10.  
    11. Install a wood block between the mount and frame, then lower the engine onto the block.
    12.  
    13. Disconnect the pipes from the manifolds.
    14.  
    15. Lower the van, then loosen the bolts and remove the manifold.
    16.  

    To install:
    1. Apply anti-seize compound to the manifold retaining bolts.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 11: Exhaust manifold bolt tightening sequence-1989-94 diesel engines

    1. Tighten the bolts to 35 ft. lbs. (47 Nm) in the sequence illustrated.
    2.  
    3. Raise the van and support it with safety stands.
    4.  
    5. Raise the engine so that the block of wood may be removed and lower the engine to the crossmember.
    6.  
    7. On the right-hand engine mount, install and tighten the retainers.
    8.  
    9. Engage the muffler inlet pipe to the manifold and tighten the retainers to 25-36 ft. lbs. (34-39 Nm).
    10.  
    11. Lower the van.
    12.  
    13. If removed, install the engine oil and transmission dipstick tubes, along with the dipsticks, and tighten the retainers.
    14.  
    15. If removed, install the radiator fan shroud.
    16.  
    17. Connect the negative battery cables and install the engine cover.
    18.  
    19. Start the van and check for leaks.
    20.  

    1995-96 MODELS-RIGHT-HAND MANIFOLD

    See Figure 12

    1. Disconnect the negative battery cables.
    2.  
    3. Remove the engine cover.
    4.  


    CAUTION
    When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

    1. Drain the cooling system.
    2.  
    3. Remove the air cleaner housing.
    4.  
    5. Disconnect the upper radiator hose and the coolant recovery reservoir hose.
    6.  


    CAUTION
    The fan clutch uses a right-hand thread nut. Remove the nut by turning it counterclockwise.

    1. Using clutch nut wrench T83T-6312-B and clutch pulley holder T94T-6312-AH or their equivalents, loosen the clutch nut and set the fan and clutch assembly in the fan shroud.
    2.  
    3. Loosen the fan shroud retainers, then remove the shroud and the fan/clutch assembly
    4.  
    5. Remove the drive belt.
    6.  
    7. Disengage the alternator electrical connections, loosen the retainers and remove the alternator.
    8.  
    9. Loosen the engine oil dipstick tube-to-engine retainers and tube.
    10.  
    11. Raise the van and support it with safety stands.
    12.  



    Click image to see an enlarged view

    Fig. Fig. 12: Right side exhaust manifold mounting-1995-96 diesel engines

    1. Loosen the bolts retaining the right turbocharger exhaust inlet pipe to the exhaust manifold.
    2.  
    3. Lower the van, then disengage the exhaust back pressure line from the manifold.
    4.  
    5. Loosen the exhaust manifold bolts, then remove the manifold.
    6.  
    7. Clean the manifold mating surfaces and check them for warpage using a straightedge. The maximum allowable warpage is 0.005 in. (0.13mm).
    8.  

    To install:
    1. Apply anti-seize compound to the manifold bolt threads.
    2.  
    3. If applicable, install the manifold gasket.
    4.  
    5. Install the manifold and the retainers, then tighten the retainers to 45 ft. lbs. (61 Nm).
    6.  
    7. Connect the exhaust backpressure line to manifold.
    8.  
    9. Raise the van and support it with safety stands.
    10.  
    11. Install the right turbocharger exhaust inlet pipe-to-manifold bolts and tighten them to 36 ft. lbs. (49 Nm).
    12.  
    13. Lower the van and install the engine oil dipstick tube and tighten the retainers.
    14.  
    15. Install the alternator and drive belt, then engage the electrical connections.
    16.  
    17. Install the fan shroud and the fan/clutch assembly. Tighten the shroud retainers to 44-71 inch lbs. (5-8 Nm).
    18.  


    CAUTION
    The fan clutch uses a right-hand thread nut. Install the nut by turning it clockwise.

    1. Using clutch nut wrench T83T-6312-B and clutch pulley holder T94T-6312-AH or their equivalents, tighten the clutch nut.
    2.  
    3. Install the radiator coolant recovery tank hose and the upper radiator hose.
    4.  
    5. Install the air cleaner housing.
    6.  
    7. Refill and bleed the cooling system and connect the negative battery cables.
    8.  

    When the battery is disconnected and reconnected, some abnormal drive systems may occur while the Powertrain Control Module (PCM) relearns the adaptive strategy. The van may need to be driven 10 miles or more for the strategy to be relearned.

    1. Install the engine cover.
    2.  

    1995-96 MODELS-LEFT-HAND MANIFOLD

    See Figure 13

    1. Raise the van and support it with safety stands.
    2.  
    3. Loosen the bolts retaining the turbocharger exhaust inlet pipe to the manifold.
    4.  
    5. Loosen the exhaust manifold retainers and remove the manifold.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 13: Loosen the retainers and remove the left-hand exhaust manifold-1995-96 diesel engines

    1. Clean the manifold mating surfaces and check them for warpage using a straightedge. The maximum allowable warpage is 0.005 in. (0.13mm).
    2.  

    To install:
    1. Apply anti-seize compound to the manifold bolt threads.
    2.  
    3. If applicable, install the manifold gasket.
    4.  
    5. Install the manifold and the retainers, then tighten the retainers to 45 ft. lbs. (61 Nm).
    6.  
    7. Install the bolts retaining the turbocharger exhaust inlet pipe to the manifold. Tighten the bolts to 36 ft. lbs. (49 Nm).
    8.  
    9. Lower the van and check for proper operation.
    10.  

     
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