How to replace Exhaust Manifold On Ford Mustang?

The details to replace Exhaust Manifold for 2010 Ford Mustang and other Mustang years are as follows:----


Exhaust Manifold
REMOVAL & INSTALLATION Procedure is mentioned below:---

Its for 4.0L, 4.6L, 5.4L.

Removal & Installation

4.0L Engine
LH Side

Specific to:

Ford Mustang 2009-2010

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the 2 catalytic converter-to-exhaust manifold nuts. Discard the nuts.
3. Disconnect the EGR system module tube from the exhaust manifold.
4. Remove the 6 nuts, the LH exhaust manifold and the gasket. Discard the nuts and gasket.
5. Clean and inspect the LH exhaust manifold.
6. Remove and discard the 6 LH exhaust manifold studs. 
   
   
   
   

   Fig. Exploded view of the RH exhaust manifold

To install:

1. Install the 6 new LH exhaust manifold studs. Tighten to 106 inch lbs. (12 Nm).
2. Install the new LH exhaust manifold gasket, manifold and 6 new nuts. Tighten to 17 ft. lbs. (23 Nm).
3. Connect the EGR system module tube to the exhaust manifold. Tighten to 30 ft. lbs. (40 Nm).
4. Install the 2 new catalytic converter-to-exhaust manifold nuts. Tighten to 33 ft. lbs. (45 Nm).

RH Side

Specific to:

Ford Mustang 2009-2010

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the 2 catalytic converter-to-exhaust manifold nuts. Discard the nuts.
3. Remove the nuts, the RH exhaust manifold and the gasket. Discard the nuts and gasket.
4. Clean and inspect the RH exhaust manifold.
5. Remove and discard the 6 RH exhaust manifold studs.
   
   
   

   

   Fig. Exploded view of the RH exhaust manifold

To install:

1. Install the 6 new RH exhaust manifold studs. Tighten to 106 inch lbs. (12 Nm).
2. Install the new RH exhaust manifold gasket, manifold and 6 new nuts. Tighten to 17 ft. lbs. (23 Nm).
3. Install the 2 new catalytic converter-to-exhaust manifold nuts. Tighten to 33 ft. lbs. (45 Nm).

4.6L Engine
Left Side

Specific to:

Ford Mustang 2009-2010

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the battery ground cable.
3. Remove the Air Cleaner (ACL) assembly.
4. Remove the Throttle Body (TB).
5. Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector and wiring retainer.
6. Remove the 2 RH catalytic converter-to-exhaust manifold nuts.
7. Remove the 2 LH catalytic converter-to-exhaust manifold nuts.
8. Remove the 6 pin-type retainers and the radiator sight shield.
9. Using a suitable belt tensioner release tool, rotate the accessory drive belt tensioner clockwise and position the accessory drive belt aside from the generator pulley.
10. Remove the 2 outer generator bracket bolts.
11. Remove the 2 lower generator nuts.
12. Disconnect the generator electrical connector and pin-type retainers.
13. Position the B+ terminal cover aside and remove the B+ terminal nut. Remove the generator.
14. Install the Engine Lifting Brackets.
15. If equipped, remove the 4 nuts and the strut tower cross brace.
16. Install the Engine Support Bar.
    
    NOTE

    Both the RH and LH engine support insulator nuts must be removed to allow the engine to be raised.
17. Remove the RH and LH engine support insulator nuts.
18. Using the Engine Support Bar, raise the engine 1.57 inch (40 mm).
    
    NOTE

    Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
19. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
    
    NOTE

    Do not allow the steering wheel to rotate while the steering column intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the wheel has rotated, the clockspring must be removed and recentered.
20. Remove the bolt and disconnect the steering coupling. Discard the bolt.
21. Remove the 4 bolts and the LH engine support insulator bracket.
22. Remove the 8 nuts and the exhaust manifold. Discard the nuts and gaskets.
23. Clean and inspect the LH exhaust manifold.
24. Remove and discard the 8 LH exhaust manifold studs.
    
    NOTE

    Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.
25. Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging.
    
    
    

    

    Fig. Exploded view of the LH exhaust manifold (4.6L engine)

To install:

1. Install 8 new LH exhaust manifold studs. Tighten to 106 inch lbs. (12 Nm).
2. Install new exhaust manifold gaskets.
3. Install the exhaust manifold and 8 new nuts. Tighten the nuts in the sequence shown to 18 ft. lbs. (25 Nm).
   
   
   

   

   Fig. Identifying the exhaust manifold nut tightening sequence (LH side)
4. Install the LH engine support insulator bracket and the 4 bolts. Tighten to 41 ft. lbs. (55 Nm).
   
   NOTE

   Do not allow the steering wheel to rotate while the steering column intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the wheel has rotated, the clockspring must be removed and recentered.
5. Connect the steering coupling and install the new bolt. Tighten to 18 ft. lbs. (25 Nm).
6. Using the Engine Support Bar, lower the engine.
7. If equipped, install the strut tower cross brace and the 4 nuts. Tighten to 26 ft. lbs. (35 Nm).
8. Install the RH and LH engine support insulator nuts. Tighten to 46 ft. lbs. (63 Nm).
9. Install the 2 LH catalytic converter-to-exhaust manifold nuts. Tighten to 30 ft. lbs. (40 Nm).
10. Install the 2 RH catalytic converter-to-exhaust manifold nuts. Tighten to 30 ft. lbs. (40 Nm).
11. Connect the LH HO2S electrical connector and wiring retainer.
    
    NOTE

    Make sure the B+ cable is positioned close to the generator when the nut is being tightened.
12. Position the generator and install the B+ terminal and nut. Tighten to 71 inch lbs. (8 Nm).
13. Connect the generator electrical connector and pin-type retainers.
14. Install the 2 lower generator nuts. Tighten to 18 ft. lbs. (25 Nm).
15. Install the 2 outer generator bracket bolts. Tighten to 89 inch lbs. (10 Nm).
16. Using a suitable belt tensioner release tool, rotate the accessory drive belt tensioner clockwise and position the accessory drive belt onto the generator pulley.
17. Install the radiator sight shield and 6 pin-type retainers.
18. Install the TB .
19. Install the ACL assembly.
20. Connect the battery ground cable.

Right Side

Specific to:

Ford Mustang 2009-2010

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the battery ground cable.
3. Remove the Air Cleaner (ACL) assembly.
4. Remove the Throttle Body (TB).
5. Remove the starter.
6. Remove the 2 RH catalytic converter-to-exhaust manifold nuts.
7. Remove the 2 LH catalytic converter-to-exhaust manifold nuts.
8. Remove the 6 pin-type retainers and the radiator sight shield.
9. Using a suitable belt tensioner release tool, rotate the accessory drive belt tensioner clockwise and position the accessory drive belt aside from the generator pulley.
10. Remove the 2 outer generator bracket bolts.
11. Remove the 2 lower generator nuts.
12. Disconnect the generator electrical connector and pin-type retainers.
13. Position the B+ terminal cover aside and remove the B+ terminal nut. Remove the generator.
14. Install the Engine Lifting Brackets.
15. If equipped, remove the 4 nuts and the strut tower cross brace.
16. Install the Engine Support Bar.
    
    NOTE

    Both the RH and LH engine support insulator nuts must be removed to allow the engine to be raised.
17. Remove the RH and LH engine support insulator nuts.
18. Using the Engine Support Bar, raise the engine 1.57 inch (40 mm).
19. Remove the nut and the ground wire from the stud bolt.
20. If equipped, remove the nut and position aside the transmission cooler tube bracket.
21. Remove the 2 bolts, 2 stud bolts and the RH engine support bracket.
22. Remove the 8 nuts and the exhaust manifold. Discard the nuts and gaskets.
23. Clean and inspect the RH exhaust manifold.
24. Remove and discard the 8 RH exhaust manifold studs.
    
    NOTE

    Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.
25. Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging.
    
    
    

    

    Fig. Exploded view of the generator and radiator sight shield
    
    
    
    

    

    Fig. Exploded view of the RH engine support insulator and RH/LH catalytic converter fasteners
    
    
    
    

    

    Fig. Exploded view of the RH exhaust manifold

To install:

1. Install 8 new RH exhaust manifold studs. Tighten to 106 inch lbs. (12 Nm).
2. Install new exhaust manifold gaskets.
3. Install the exhaust manifold and 8 new nuts. Tighten the nuts in the sequence shown to 18 ft. lbs. (25 Nm).
   
   
   

   

   Fig. Identifying the RH exhaust manifold nut tightening sequence
4. Install the RH engine support insulator bracket, the 2 bolts and 2 stud bolts. Tighten to 41 ft. lbs. (55 Nm).
5. If equipped, install the transmission cooler tube bracket and nut. Tighten to 18 ft. lbs. (25 Nm).
6. Install the ground wire and nut onto the stud bolt. Tighten to 18 ft. lbs. (25 Nm).
7. Using the Engine Support Bar, lower the engine.
8. If equipped, install the strut tower cross brace and the 4 nuts. Tighten to 26 ft. lbs. (35 Nm).
9. Install the RH and LH engine support insulator nuts. Tighten to 46 ft. lbs. (63 Nm).
10. Install the 2 LH catalytic converter-to-exhaust manifold nuts. Tighten to 30 ft. lbs. (40 Nm).
11. Install the 2 RH catalytic converter-to-exhaust manifold nuts. Tighten to 30 ft. lbs. (40 Nm).
    
    NOTE

    Make sure the B+ cable is positioned close to the generator when the nut is being tightened.
12. Position the generator and install the B+ terminal and nut. Tighten to 71 inch lbs. (8 Nm).
13. Connect the generator electrical connector and pin-type retainers.
14. Install the 2 lower generator nuts. Tighten to 18 ft. lbs. (25 Nm).
15. Install the 2 outer generator bracket bolts. Tighten to 89 inch lbs. (10 Nm).
16. Using a suitable belt tensioner release tool, rotate the accessory drive belt tensioner clockwise and position the accessory drive belt onto the generator pulley.
17. Install the radiator sight shield and 6 pin-type retainers.
18. Install the starter.
19. Install the TB.
20. Install the ACL assembly.
21. Connect the battery ground cable.

5.4L Engine
Left Side

Specific to:

Ford Mustang 2009-2010

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the Evaporative Emission (EVAP) canister purge valve.
3. Remove the 2 dash boot nuts.
4. Remove the catalytic converter.
5. Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector.
6. Remove and discard the engine oil filter.
   
   NOTE

   Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
7. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
   
   NOTE

   Do not allow the steering wheel to rotate while the steering column intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the wheel has rotated, the clockspring must be removed and recentered.
8. Remove the upper bolt from the intermediate steering shaft and position the intermediate steering shaft aside.
   
   
   

   

   Fig. Removing the upper bolt from the intermediate steering shaft and positioning the intermediate shaft aside
9. Remove the 8 nuts and the LH exhaust manifold. Discard the nuts and gaskets.
10. Clean and inspect the LH exhaust manifold.
11. Remove and discard the 8 LH exhaust manifold studs.
    
    
    

    

    Fig. Exploded view of the LH exhaust manifold (1 of 2) (5.4L Engine)
    
    
    
    

    

    Fig. Exploded view of the LH exhaust manifold (2 of 2) (5.4L Engine)

To install:

NOTE

Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

1. Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.
2. Install 8 new LH exhaust manifold studs. Tighten to 106 inch lbs. (12 Nm).
3. Install new gaskets, the LH exhaust manifold and 8 new nuts. Tighten in the sequence shown to 177 inch lbs. (20 Nm).
   
   NOTE

   Do not allow the steering wheel to rotate while the steering column intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the wheel has rotated, the clockspring must be removed and recentered.
   
   
   
   
   

   

   Fig. Installing the LH exhaust manifold
4. Install the intermediate steering shaft and the upper bolt. Tighten to 35 ft. lbs (47 Nm).
   
   
   

   

   Fig. Installing the intermediate steering shaft
5. Install a new engine oil filter.
   1. Lubricate the oil filter gasket with clean engine oil and tighten until the seal makes contact.
   2. Using an oil filter strap wrench, tighten the filter an additional 270°.
6. Connect the LH HO2S electrical connector.
7. Install the catalytic converter.
8. Install the 2 dash boot nuts. Tighten to 80 inch lbs. (9 Nm).
9. Install the EVAP canister purge valve.

Right Side

Specific to:

Ford Mustang 2009-2010

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the 4 nuts and the strut tower cross brace.
3. Remove the EGR tube.
4. Remove the catalytic converter.
5. Rotate the Supercharger (SC) drive belt tensioner clockwise and remove the drive belt from the SC drive pulley.
   
   
   

   

   Fig. Removing the drive belt from the SC drive pulley
6. Install the Engine Lifting Bracket.
   
   NOTE

   The heavy duty Engine Support Bar (303-F070) must be used with the draw screws from the light duty Engine Support Bar (303-F072). This will provide enough clearance between the SC and the Engine Support Bar, and enough clearance between the draw screw and the vehicle hood.
7. Install the Engine Support Bars.
   1. Remove the RH engine support insulator nut.
   2. Using the Engine Support Bars, raise the RH side of the engine.
      
      
      

      

      Fig. Installing the engine support bars
8. Remove the SC drive belt from the A/C compressor pulley.
9. Remove the wiring harness retainers from the A/C compressor stud bolts and position the wiring harness aside.
   
   NOTE

   The A/C compressor stud bolts must be loosened to gain access to the RH exhaust manifold nuts.
10. Loosen the A/C compressor stud bolts 0.98 inch (25 mm).
11. Remove the 8 nuts and the RH exhaust manifold. Discard the nuts and gaskets.
12. Clean and inspect the RH exhaust manifold.
13. Remove and discard the 8 RH exhaust manifold studs.
    
    
    

    

    Fig. Exploded view of the RH exhaust manifold

Installation

NOTE

Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

1. Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.
2. Install the 8 new RH exhaust manifold-to-cylinder head studs. Tighten to 106 inch lbs. (12 Nm).
3. Install new gaskets, the RH exhaust manifold and 8 new nuts. Tighten in the sequence shown to 177 inch lbs. (20 Nm).
   
   
   

   

   Fig. Identifying the RH exhaust manifold nut tightening sequence
4. Tighten the A/C compressor stud bolts to 25 Nm (18 lb-ft).
5. Install the wiring harness retainers onto the A/C compressor stud bolts.
6. Position the SC drive belt onto the A/C compressor pulley.
7. Using the Engine Support Bars, lower the engine onto the engine support insulator.
8. Install the RH engine support insulator nut. Tighten to 46 ft. lbs. (63 Nm).
9. Rotate the SC drive belt tensioner clockwise and install the drive belt onto the SC drive pulley.
10. Install the catalytic converter.
11. Install the EGR tube.
12. Install the strut tower cross brace and the 4 nuts. Tighten to 26 ft. lbs. (35 Nm).

These details will help.

Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html