How to Replace the Exhaust Manifold in a Ford F-150

The Ford F-Series has been around since 1948, offering a dizzying array of body styles and performance options over the years. The 4.6L and 5.4L engines power the F-150 manufactured from 2001 to 2003 as well as the 2004 Heritage Editions. The procedure for removing and installing the exhaust manifold is the same for the left side engines.

Instructions

Remove the Exhaust Manifold

1

Raise the truck. Make sure the support is secure. Take off the front wheel opening molding on vehicles equipped with the 4x4 option. Unbolt and remove the front fender splash guard.

2

Remove the nut and the brake booster vacuum hose and bracket. Locate the EGR valve tube and remove it.

3

Loose the nuts and take the exhaust manifold from the engine. Take off the gasket and discard it. Clean the gasket debris from the manifold surfaces and inspect them for damage.

Install the Exhaust Manifold

4

Set the exhaust manifold gasket in place. Position the manifold over it and install the nuts by hand.

5

Tighten the manifold nuts in sequence, alternating sides. Torque the nuts in three passes to 18 foot pounds. Install the catalytic converter.

6

Install the differential pressure feedback EGR system in the 4.6L engine and then install the electrical connector. Hand-tighten both fittings at first, starting at the top, then torque the nuts to 26 to 33 foot pounds.

7

Install both fittings in the 5.4L engine. Hand-tighten the nuts first, starting at the top. Torque the nuts then to 30 to 44 foot pounds. Reconnect the differential pressure feedback EGR system hoses.

8

Reconnect the brake booster vacuum hose with the bracket and bolt on both engines. Replace the front fender splash shield. Replace the front wheel opening molding on a 4x4 model.

9

Lower the vehicle carefully. Start the engine. Check for exhaust leaks.