Monday, March 12, 2012

How to Replace Exhaust Manifold on Ford Windstar?

The exhaust manifold replacing procedure is as follows :----


Exhaust Manifold
REMOVAL & INSTALLATION Details are as follows:----




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.

3.0L Engine
Front Manifold
  1. Disconnect the negative battery cable.
  2. Remove the oil level indicator tube support bracket and retaining nut.
  3. Remove the oil level dipstick and oil level indicator tube.
  4. Raise and support the vehicle safely.
  5. Disconnect the dual converter Y-pipe from the exhaust manifold.
  6. Lower the vehicle.
  7. Remove the exhaust manifold.
To install:
  1. Clean all mating surfaces thoroughly.
  2. Position exhaust manifold and tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
  3. Raise and support the vehicle safely.
  4. Connect the dual converter Y-pipe and tighten the bolts to 25-34 ft. lbs. (34-47 Nm).
  5. Lower the vehicle.
  6. Install the oil level dipstick and oil level indicator tube. Tighten the nut to 11-14 ft. lbs. (15-20 Nm).
  7. Connect the negative battery cable.
  8. Start the engine and check for exhaust leaks.
Rear Manifold
  1. Disconnect the negative battery cable.
  2. Remove the cowl vent panel.
  3. Label and disconnect the EGR backpressure transducer hoses.
  4. Remove the EGR valve tube from the exhaust manifold.
    NOTE
    Use a backup wrench to prevent damaging the tube.
  5. Raise and support the vehicle safely.
  6. Disconnect the dual converter Y-pipe from the exhaust manifold.
  7. Lower the vehicle.
  8. Remove the exhaust manifold.
To install:
  1. Clean all mating surfaces thoroughly.
  2. Position the exhaust manifold and tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
  3. Raise and support the vehicle safely.
  4. Connect the dual converter Y-pipe and tighten the bolts to 25-34 ft. lbs. (34-47 Nm).
  5. Lower the vehicle.
  6. Install the EGR valve tube and tighten the fitting to 26-48 ft. lbs. (35-65 Nm).
  7. Connect the EGR backpressure transducer hoses.
  8. Install the cowl vent panel.
  9. Connect the negative battery cable.
  10. Start the engine and check for exhaust leaks.
3.8L Engine
Front Manifold
  1. Disconnect the negative battery cable.
  2. Remove the oil level indicator tube.
  3. Label and disconnect the ignition wires from the front cylinder head.
  4. Disconnect the EGR-to-exhaust manifold tube.
  5. Raise and support the vehicle safely on jackstands.
  6. Disconnect the dual converter Y-pipe from the exhaust manifold.
  7. Lower the vehicle.
  8. Remove the exhaust manifold.
To install:
  1. Clean all gasket mating surfaces thoroughly.
    NOTE
    A slight warpage in the exhaust manifold may cause a misalignment between the bolt holes 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.
  2. Install a new gasket and the exhaust manifold on the cylinder head. Start 2 bolts to hold the manifold in position.
  3. Install the remaining bolts. Tighten the bolts, starting from the center port and working outward, to 15-22 ft. lbs. (20-30 Nm).
  4. Raise and support the vehicle safely on jackstands.
  5. Connect the dual converter Y-pipe and tighten the bolts to 25-34 ft. lbs. (34-47 Nm).
  6. Lower the vehicle.
  7. Connect the EGR to the exhaust manifold tube.
  8. Connect the ignition wires.
  9. Install the oil level indicator tube.
  10. Connect the negative battery cable.
  11. Start the engine and check for exhaust leaks.
Rear Manifold
  1. Disconnect the negative battery cable.
  2. Remove the cowl vent panel.
  3. Remove the engine air cleaner and air cleaner outlet tube.
  4. Disconnect the ignition wires from the rear cylinder head and ignition coil.
  5. Remove the spark plugs from the rear cylinder head.
  6. Raise and support the vehicle safely on jackstands.
  7. Disconnect the dual converter Y-pipe from the exhaust manifold.
  8. Lower the vehicle.
  9. Remove the exhaust manifold.
To install:
  1. Clean all gasket mating surfaces thoroughly.
    NOTE
    A slight warpage in the exhaust manifold may cause a misalignment between the bolt holes 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.
  2. Install a new exhaust manifold gasket and the exhaust manifold on the cylinder head. Start 2 bolts to hold the manifold in position.
  3. Install the remaining bolts. Tighten the bolts beginning from the center port and working outward to 15-22 ft. lbs. (20-30 Nm).
  4. Raise and support the vehicle safely.
  5. Connect the dual converter Y-pipe and tighten the bolts to 25-34 ft. lbs. (34-47 Nm).
  6. Lower the vehicle.
  7. Install the spark plugs in the rear cylinder head.
  8. Connect the ignition wires.
  9. Install the engine air cleaner and air cleaner outlet tube.
  10. Install the cowl vent panel.
  11. Connect the negative battery cable.
  12. Start the engine and check for exhaust leaks.


This will help.
Thanks.



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