Exhaust Manifold: Installation

WARNING: This page is about a different car, the 2004 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.

Attach the exhaust manifold to the cylinder head using the alignment spacers with the two outside bolts and a new manifold gasket.

Fig 1: Attaching Exhaust Manifold To Cylinder Head
Courtesy of FORD MOTOR CO.

CAUTION: Always follow the correct installation sequence for the catalytic converter in order to prevent damage.

CAUTION: Do not allow debris to fall into the exhaust manifold.

NOTE: Examine the threads in the exhaust catalyst cone and EGR. Clean as required.

Fig 2: Loosening Bracket For Catalytic Converter

Courtesy of FORD MOTOR CO.

Loosen the bracket for the catalytic converter so that it can move freely.

NOTE: Use a new gasket.

NOTE: Do not fully tighten the nuts/bolts at this stage.

Fig 3: Positioning Catalytic Converter On Exhaust Manifold

Courtesy of FORD MOTOR CO.

Position the catalytic converter on the exhaust manifold using new hardware.
Raise and support the vehicle. For additional information, refer to JACKING AND LIFTING .
Using a nut and bolt, temporarily secure the catalytic converter to the bracket at the rear.

Fig 4: Securing Catalytic Converter To Bracket At Rear
Courtesy of FORD MOTOR CO.
Tighten the catalytic converter to the exhaust manifold.

Fig 5: Tightening Catalytic Converter To Exhaust Manifold
Courtesy of FORD MOTOR CO.

NOTE: Always use a new catalyst to EGR valve pipe assembly.

NOTE: Loosely assemble the pipe to both the EGR valve and the exhaust catalyst before tightening the unions.

Fig 6: Attaching Heat Shield

Courtesy of FORD MOTOR CO.

Attach the catalytic converter.
1. Tighten the bolts on the catalytic converter bracket.
2. Install a new EGR-pipe.
3. Attach the heat shield.
Attach the bracket for the catalytic converter.
- Tighten the bolts.
- Remove the temporary bolt from the rear catalytic converter bracket.
Fig 7: Removing Temporary Bolt From Rear Catalytic Converter Bracket
Courtesy of FORD MOTOR CO.
Lower the vehicle.
Attach the air filter housing.
- Press the air filter housing into the rubber bushings.
1. Push on the mass air flow (MAF) sensor multiplug.
2. Attach the PCV hose.
3. Attach the intake hose.
Fig 8: Attaching Intake Hose
Courtesy of FORD MOTOR CO.