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Home >> Ford >> 2003 >> ZX2 Automatic >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine >> In-Vehicle Repair >> Exhaust Manifold >> Removal
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Exhaust Manifold: Removal

  1. Disconnect the battery ground cable (14301).
  2. Disconnect the engine cooling fan motor wiring. For additional information, refer to REMOVAL .
  3. Remove the fan shroud (8146). For additional information, refer to REMOVAL .
  4. Raise the vehicle. For additional information, refer to JACKING & HOISTING .
  5. CAUTION: When repairing the exhaust system or removing exhaust components, disconnect the heated oxygen sensor (HO2S) (9F472) at the wiring harness to prevent damage to the sensors and the harness.
  6. Disconnect the heated oxygen sensor wiring connector.
  7. Disconnect the catalytic converter from the exhaust manifold (9430).
    • Remove the bolt and the nut.
    • Disconnect the converter from the exhaust manifold.
    Fig 1: Disconnecting Converter From Exhaust Manifold
    G01371025Courtesy of FORD MOTOR CO.
  8. Lower the vehicle.
  9. CAUTION: Do not break the threadlock seal on the oil level indicator tube (6754). Relock if seal is broken to prevent an oil leak from cylinder block (6010).
    Fig 2: Removing Oil Level Indicator Tube Bracket Bolt
    G01371026Courtesy of FORD MOTOR CO.
  10. Remove the oil level indicator tube bracket bolt.
  11. Remove the bolts, nuts and remove the exhaust manifold heat shield.
    Fig 3: Removing Exhaust Manifold Heat Shield Bolts/Nuts
    G01371027Courtesy of FORD MOTOR CO.
  12. CAUTION: Do not work on the aluminum engine components until the engine is cold or damage may occur.
    Fig 4: Removing Exhaust Manifold Bolts/Two Studs In Sequence
    G01371028Courtesy of FORD MOTOR CO.
  13. Remove the exhaust manifold.
    • Remove the exhaust manifold.
    • Remove the seven bolts and two studs in the sequence shown in Fig 4.
    • Remove the exhaust manifold.
    • Discard the exhaust manifold gasket (9448).