How to replace Exhaust Manifold on Ford Fusion & Mercury Milan?

The procedure is similar for both Ford, Lincoln and Mercury car models:----

Exhaust Manifold

Removal & Installation

2.3L Engine

Specific to:

Ford Fusion 2008-2009

Mercury Milan 2008-2009

1. Raise and safely support the vehicle.
2. Remove the generator air inlet duct.
3. Remove the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS).
4. Remove the wiring harness bracket from the valve cover stud and position it aside.
5. Remove the 2 catalytic converter manifold-to-exhaust flexible pipe nuts.
6. Discard the gasket and the 2 nuts.
7. Remove the 6 heat shield bolts and the heat shield.
8. Remove the 2 catalytic converter manifold shield bracket bolts and the bracket.
9. Loosen the 2 catalytic converter manifold bracket bolts.
10. Remove the 7 nuts and the catalytic converter manifold.
11. Discard the 7 nuts and the gasket.
12. Remove and discard the 7 catalytic converter manifold studs.
13. Clean and inspect the catalytic converter manifold.

To install:

1. Install the 7 new catalytic converter manifold studs. Tighten to 13 ft. lbs. (17 Nm).
2. Position a new catalytic converter manifold gasket on the studs.
   
   WARNING

   Failure to tighten the catalytic converter manifold nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak.
   
   
   
   WARNING

   Failure to tighten the catalytic converter manifold nuts to specification a second time will cause the converter to develop an exhaust leak.
   
   
   
   NOTE

   Make sure to tighten the nuts in the sequence shown in 2 stages.
3. Position the catalytic converter manifold and tighten the 7 new nuts in the sequence shown, in 2 stages:
   1. Step 1: Tighten to 41 ft. lbs. (55 Nm).
   2. Step 2: Tighten to 41 ft. lbs. (55 Nm). 
      
      
      
      Fig. Catalytic converter manifold tightening sequence-2.3L engine
4. Install the 2 catalytic converter manifold shield bracket bolts and the bracket. Tighten to 15 ft. lbs. (20 Nm).
5. Tighten the 2 catalytic converter manifold bracket bolts. Tighten to 15 ft. lbs. (20 Nm).
6. Position the heat shield and install the 6 heat shield bolts. Tighten to 89 inch lbs. (10 Nm).
7. Install the 2 catalytic converter manifold-to-exhaust flexible pipe nuts. Install a new gasket. Tighten to 30 ft. lbs. (40 Nm).
8. Position the wiring harness bracket on the stud.
9. Install the HO2S and CMS.
10. Install the generator air inlet duct

3.0L Engine
Left Side

Specific to:

Ford Fusion 2008-2009

Mercury Milan 2008-2009

1. Raise and safely support the vehicle.
2. Remove and discard the oil filter.
3. Remove the oil level indicator and tube.
4. Remove the Heated Oxygen Sensor (HO2S) and the Catalyst Monitor Sensor (CMS).
5. Remove the 2 LH catalytic converter-to-exhaust flexible pipe nuts. Discard the gasket and the 2 nuts.
6. Remove the 4 bolts and the LH catalytic converter manifold shield.
7. Remove the 2 LH catalytic converter manifold shield bracket bolts and the shield bracket.
8. Loosen the 2 LH catalytic converter manifold bracket bolts.
9. Remove the 6 nuts and the LH catalytic converter manifold.
10. Discard the 6 LH catalytic converter manifold nuts and the gasket.
11. Remove and discard the 6 LH catalytic converter manifold studs.
12. Clean and inspect the manifold.

To install:

1. Install the 6 new LH catalytic converter manifold studs. Tighten to 8 ft. lbs. (11 Nm).
2. Position a new LH catalytic converter manifold gasket on the studs.
3. Position the LH catalytic converter manifold and finger-tighten the 6 new nuts.
4. Install a new gasket and the 2 nuts at the LH catalytic converter-to-exhaust flexible pipe. Tighten to 30 ft. lbs. (40 Nm).
   
   WARNING

   Failure to tighten the catalytic converter manifold nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak.
   
   
   
   WARNING

   Failure to tighten the catalytic converter manifold nuts to specification a second time will cause the converter to develop an exhaust leak.
   
   
   
   NOTE

   Make sure to tighten the nuts in the sequence shown in 2 stages.
5. Position the LH catalytic converter manifold and tighten the 6 new nuts in the sequence shown, in 2 stages:
   1. Step 1: Tighten to 15 ft. lbs. (20 Nm).
   2. Step 2: Tighten to 15 ft. lbs. (20 Nm).
      
      
      

      

      Fig. Left side catalytic converter manifold bolt tightening sequence-3.0L engine
6. Install the shield bracket and the 2 LH catalytic converter manifold shield bracket bolts. Tighten to 15 ft. lbs. (20 Nm).
7. Tighten the 2 LH catalytic converter manifold bracket bolts. To install, tighten to 15 ft. lbs. (20 Nm).
8. Position the LH catalytic converter manifold shield and install the 4 bolts. Tighten to 89 inch lbs. (10 Nm).
9. Install the 2 LH catalytic converter-to-exhaust flexible pipe nuts in 3 stages:
   1. Step 1: Tighten the passenger side nut to 44 inch lbs. (5 Nm).
   2. Step 2: Tighten the driver side nut to 30 ft. lbs. (40 Nm).
   3. Step 3: Tighten the passenger side nut to 30 ft. lbs. (40 Nm).
10. Install the HO2S and the CMS.
11. Install the oil level indicator and tube.
12. Install a new oil filter. Tighten to 44 inch lbs. (5 Nm) and then rotate an additional 180 degrees.

Right Side-AWD Models

Specific to:

Ford Fusion 2008-2009

Mercury Milan 2008-2009

1. Raise and safely support the vehicle.
2. Remove the Exhaust Gas Recirculation (EGR) tube.
3. Remove the RH catalytic converter.
   
   NOTE

   The heat shield that was unbolted from the exhaust manifold during removal of the RH catalytic converter, cannot be removed from the vehicle until the power steering rack heat shield is removed.
4. Remove the 2 bolts and the power steering rack heat shield.
5. Remove the catalytic converter heat shield from the vehicle.
6. Remove the 6 nuts and the RH exhaust manifold. Discard the gasket and nuts.
7. Remove and discard the 6 RH catalytic converter studs.

To install:

1. Install 6 new RH catalytic converter studs. Tighten to 9 ft. lbs. (12 Nm).
   
   NOTE

   The catalytic converter heat shield must be positioned up into the engine compartment prior to installing the power steering rack heat shield.
2. Position the catalytic converter heat shield into the engine compartment.
3. Install the power steering rack heat shield and the 2 bolts. Tighten to 11 ft. lbs. (15 Nm).
4. Install a new gasket, the RH exhaust manifold and 6 new nuts. Tighten to 15 ft. lbs. (20 Nm) in the sequence shown.
   
   
   

   

   Fig. Right side exhaust manifold tightening sequence-3.0L engine, AWD models
5. Install the RH catalytic converter.
6. Install the EGR tube

Right Side-FWD Models

Specific to:

Ford Fusion 2008-2009

Mercury Milan 2008-2009

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the exhaust flexible pipe.
3. Remove the Exhaust Gas Recirculation (EGR) tube.
4. Disconnect the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) electrical connectors.
5. Remove the 2 bolts and the RH catalytic converter manifold shield.
6. Remove the 2 RH catalytic converter manifold shield bracket bolts and the shield bracket.
7. Loosen the 2 RH catalytic converter manifold bracket bolts.
8. Remove the 6 nuts and the RH catalytic converter manifold.
9. Discard the 6 RH catalytic converter manifold nuts and gasket.
10. Remove the 6 RH catalytic converter manifold studs and discard.
    
    NOTE

    If installing a new RH catalytic converter manifold, remove and save the HO2S and CMS for installation in the new RH catalytic converter manifold.
11. Using special tool 303-476, or equivalent, remove the RH catalytic converter manifold HO2S and CMS.
12. Clean and inspect the manifold.

To install:

NOTE

Apply anti-seize lubricant to the threads of the HO2S and CMS before installation.

1. If installing a new RH catalytic converter manifold, install the HO2S and CMS using the special tool. Tighten to 35 ft. lbs. (47 Nm).
2. Install the 6 new RH catalytic converter manifold studs. Tighten to 8 ft. lbs. (11 Nm).
3. Position a new RH catalytic converter manifold gasket on the studs.
   
   WARNING

   Failure to tighten the catalytic converter nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak.
   
   
   
   WARNING

   Failure to tighten the catalytic converter nuts to specification a second time will cause the converter to develop an exhaust leak.
   
   
   
   NOTE

   Make sure to tighten the nuts in the sequence shown in 2 stages.
4. Position the RH catalytic converter manifold and tighten the 6 new nuts in the sequence shown, in 2 stages:
   1. Step 1: Tighten to 15 ft. lbs. (20 Nm).
   2. Step 2: Tighten to 15 ft. lbs. (20 Nm).
      
      
      

      

      Fig. Right side catalytic converter manifold bolt tightening sequence-3.0L engine, FWD models
5. Install the shield bracket and the 2 RH catalytic converter manifold shield bracket bolts. Tighten to 15 ft. lbs. (20 Nm).
6. Tighten the 2 RH catalytic converter manifold bracket bolts. Tighten to 15 ft. lbs. (20 Nm).
7. Position the RH catalytic converter manifold shield and install the 2 bolts. Tighten to 89 inch lbs. (10 Nm).
8. Connect the HO2S and CMS electrical connectors.
9. Install the EGR tube.
10. Install the exhaust flexible pipe

Left Side

Specific to:

Ford Edge 2008-2009

Lincoln MKX 2008-2009

1. Remove the LH catalytic converter, as follows:
   1. Raise and safely support the vehicle.
   2. Disconnect the catalyst monitor sensor electrical connector.
   3. Remove the exhaust Y-pipe.
   4. Remove the 2 catalytic converter support bracket-to-transmission bolts.
   5. Remove the 4 nuts and the LH catalytic converter.
   6. Discard the 4 LH catalytic converter nuts and gasket.
2. Remove the LH Heated Oxygen Sensor (HO2S).
3. Remove the 3 bolts and the LH exhaust manifold heat shield.
4. Remove the 6 nuts and the LH exhaust manifold. Discard the nuts and gasket.
5. Clean and inspect the LH exhaust manifold.
6. Remove and discard the 6 LH exhaust manifold studs.
   
   WARNING

   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.
7. Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.
   
   
   

   

   Fig. Exploded view of the left side exhaust manifold and related components

To install:

1. Install 6 new LH exhaust manifold studs and tighten to 9 ft. lbs. (12 Nm).
   
   NOTE

   Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
2. Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in the sequence shown to 15 ft. lbs. (20 Nm). Then tighten to 18 ft. lbs. (25 Nm).
   
   
   

   

   Fig. Exhaust manifold tightening sequence-left side
3. Install the LH exhaust manifold heat shield and the 3 bolts and tighten to 89 inch lbs. (10 Nm).
4. Install the LH HO2S.
   
   NOTE

   When installing the catalytic converter, always install new fasteners and gaskets. Clean the flange faces prior to new gasket installation to ensure proper sealing.
5. Install the LH catalytic converter, with new gaskets and nuts, in the reverse of the removal procedure. Tighten the retainers as follows:
   1. Catalytic converter nuts: 30 ft. lbs. (40 Nm)
   2. Catalytic converter support bracket-to-transmission bolts: 35 ft. lbs. (48 Nm).

Right Side

Specific to:

Ford Edge 2008-2009

Lincoln MKX 2008-2009

1. Remove the right side catalytic converter, as follows:
   1. Raise and safely support the vehicle.
   2. Remove the catalyst monitor sensor.
   3. Remove the exhaust Y-pipe.
   4. For All Wheel Drive (AWD) models, Remove and discard the 4 universal joint (U-joint) flange bolts and separate the front driveshaft and secure it with a piece of wire.
   5. For AWD models, remove the RH halfshaft assembly. Remove the 2 catalytic converter support bracket-to-engine block bolts.
   6. For Front Wheel Drive (FWD) models, remove the 2 bolts and the power steering rack shield.
   7. For FWD models, remove the catalytic converter support bracket-to-engine block bolt and nut.
   8. Remove the 2 nuts and the roll restrictor shield.
   9. Remove the roll restrictor bolt and rotate the engine forward.
   10. Remove the 2 bracket-to-RH catalytic converter bolts.
   11. Remove the 4 nuts and the RH catalytic converter.
   12. Discard the 4 RH catalytic converter nuts and gasket.
2. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
3. Remove the 6 nuts and the RH exhaust manifold. Discard the nuts and gasket.
4. Clean and inspect the RH exhaust manifold.
5. Remove and discard the 6 RH exhaust manifold studs.
   
   WARNING

   NEVER 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.
6. Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.
   
   
   

   

   Fig. Exploded view of the right side exhaust manifold and related components

To install:

1. Install 6 new RH exhaust manifold studs and tighten to 9 ft. lbs. (12 Nm).
   
   NOTE

   Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
2. Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in the sequence shown to 15 ft. lbs. (20 Nm). Then tighten to 18 ft. lbs. (25 Nm).
   
   
   

   

   Fig. Exhaust manifold tightening sequence-right side
3. Connect the RH HO2S electrical connector.
   
   NOTE

   When installing the catalytic converter, always install new fasteners and gaskets. Clean the flange faces prior to new gasket installation to ensure proper sealing.
4. Install the right side catalytic converter, with new gaskets and nuts, in the reverse of the removal procedure. Tighten the retainers as follows:
   1. Catalytic converter nuts: 30 ft. lbs. (40 Nm)
   2. Bracket-to-RH catalytic converter bolts: 15 ft. lbs. (20 Nm)
   3. Roll restrictor bolt: 66 ft. lbs. (90 Nm)
   4. Roll restrictor shield: 8 ft. lbs. (11 Nm)
   5. Catalytic converter support bracket-to-engine block bolt and nut (FWD models): 30 ft. lbs. (40 Nm)
   6. Power steering rack shield (FWD models): 11 ft. lbs. (15 Nm)
   7. Catalytic converter support bracket-to-engine block bolts (AWD models): 30 ft. lbs. (40 Nm)
   8. U-joint flange bolts (AWD models): 52 ft. lbs. (70 Nm)

   
   

   
   

These details will help.

Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

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