Sunday, August 7, 2011

How to change the exhaust manifold on a 2005 ford escape v6

Left Manifold
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove or disconnect the following:

    Negative battery cable
    Heated Oxygen (HO 2 S) sensor and catalyst monitor
    Splash shield
    Exhaust crossover pipe
    Drive belt
    A/C compressor and move it aside
    Exhaust manifold and discard the gasket


To install:

Click image to see an enlarged view

Fig. Left side exhaust manifold bolt torque sequence-3.0L engine

  1. Clean the sealing surfaces of any old gasket material.
  2. Install or connect the following:

    Exhaust manifold and new gasket. Torque the bolts to 15 ft. lbs. (20 Nm).
    A/C compressor. Torque the bolts to 18 ft. lbs. (20 Nm).
    Drive belt
    Exhaust crossover pipe. Torque the bolts to 30 ft. lbs. (40 Nm).
    Splash shield. Torque the bolts to 80 inch lbs. (9 Nm).
    Left side HO 2 S sensor and catalyst monitor
    Negative battery cable

  3. Start the vehicle and check for leaks, repair if necessary.

Right Manifold
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove or disconnect the following:

    Negative battery cable
    Exhaust Gas Recirculation (EGR) tube
    Alternator
    Right side Heated Oxygen (HO 2 S) sensor
    Right side exhaust manifold and discard the gasket


To install:

Click image to see an enlarged view

Fig. Right side exhaust manifold bolt torque sequence-3.0L engine

  1. Clean the sealing surfaces of any old gasket material.
  2. Install or connect the following:

    Exhaust manifold and new gasket. Torque the bolts to 15 ft. lbs. (20 Nm).
    Right side HO 2 S sensor
    Alternator
    EGR tube
    Negative battery cable

  3. Start the vehicle and check for leaks, repair if necessary.

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Also read this for more help:---

Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove or disconnect the following:

    Negative battery cable
    Catalytic converter
    Oil level indicator tube and bracket
    Exhaust manifold and discard the gasket


To install:

Click image to see an enlarged view

Fig. Exhaust manifold bolt torque sequence-2.0L engine

  1. Clean the sealing surfaces of any old gasket material.
  2. Install or connect the following:

    Exhaust manifold and new gasket. Torque the bolts to 12 ft. lbs. (16 Nm).
    Oil level indicator tube and bracket. Torque the bolt to 89 inch lbs. (10 Nm).
    Catalytic converter
    Negative battery cable

  3. Start the vehicle and check for leaks, repair if necessary.

2.3L Engine
Except Hybrid


Click image to see an enlarged view

Fig. Catalytic converter/exhaust manifold-2.3L engine, exc. Hybrid

  1. Before servicing the vehicle, refer to the Precautions Section.
    WARNING
    Do not use oil or grease-based lubricants on the insulators. They may cause deterioration of the rubber.


    WARNING
    Oil or grease-based lubricants on the insulators may cause the exhaust hanger insulator to separate from the exhaust hanger bracket during vehicle operation.


    NOTE
    Exhaust fasteners are of a torque prevailing design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components.

  2. Remove the flex pipe nuts.
  3. Remove the flex pipe gasket.
  4. Remove the manifold bracket bolts.
  5. Remove the heat shield.
  6. Remove the exhaust manifold nuts.
  7. Remove the catalyst monitor sensor.
  8. Remove the heated oxygen sensor.
  9. Remove the exhaust manifold.
  10. To install, reverse the removal procedure. Make sure to apply anti-seize lubricant to the threads of the sensors before installation. Failure to tighten the exhaust manifold nuts to specification before installing the manifold bracket bolts will cause the manifold to develop an exhaust gas leak.
  11. Observe the following torques:

    Click image to see an enlarged view

    Fig. Exhaust manifold-to-head torque sequence-2.3L engine



    Exhaust manifold-to-head, in the sequence shown: 35 ft. lbs. (47 Nm), then recheck at 35 ft. lbs. (47 Nm)
    Flex pipe-to-manifold: 18 ft. lbs. (25 Nm)
    Heated oxygen sensor: 35 ft. lbs. (47 Nm)
    Catalyst monitor sensor: 30 ft. lbs. (40 Nm)

  12. Check the exhaust system for proper alignment.

Hybrid


Click image to see an enlarged view

Fig. Exhaust manifold/catalytic converter-2.3L Hybrid engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove the exhaust flexible pipe.
  3. Remove the 2 catalytic converter bracket bolts.
    NOTE
    If installing a new converter, remove the heated oxygen sensor (HO2S) and the catalyst monitoring sensor (CMS) for installation in the new converter.

  4. Disconnect the HO 2 S and the CMS electrical connectors.
  5. Remove and discard the 7 exhaust manifold nuts.
  6. Remove the catalytic converter from the vehicle. Discard the exhaust manifold gasket.

To install:


WARNING
If the warpage is greater than 0.76 mm (0.03 inch) replace the catalytic converter.

  1. Inspect the catalytic converter for warpage across the manifold flange area.
  2. Position a new exhaust manifold gasket on the engine.
    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.

  3. Position the catalytic converter and tighten the 7 exhaust manifold nuts in the sequence shown.
    NOTE
    Apply anti-seize lubricant to the threads of the sensors before installation.



    Step 1: Tighten to 35 ft. lbs. (47 Nm).
    Step 2: Retighten to 35 ft. lbs. (47 Nm).

  4. If installing a new converter, install the HO 2 S and the CMS. Tighten to 35 ft. lbs. (47 Nm).
  5. Connect the HO 2 S and the CMS electrical connectors.
  6. Install the 2 catalytic converter bracket bolts. Tighten to 18 ft. lbs. (25 Nm).
  7. Install the exhaust flexible pipe. Tighten to 18 ft. lbs. (25 Nm)
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Intake Manifold


2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Properly relieve the fuel system pressure.
  3. Remove or disconnect the following:

    Negative battery cable
    Fuel injection supply manifold
    Throttle Position (TP) sensor electrical connector
    Idle Air Control (IAC) electrical connector and unclip the harness from the bracket
    Main engine control sensor wiring
    Connector from the bracket
    Powertrain Control Module (PCM) wire harness from the bracket
    Brake booster vacuum hose
    4 additional vacuum lines
    Positive Crankcase Ventilation (PCV) hose from the intake manifold
    Knock Sensor (KS) electrical connector
    Alternator
    Intake manifold and discard the gasket

  4. Clean the mating surfaces.

    Click image to see an enlarged view

    Fig. Intake manifold bolt loosening sequence-2.0L engine


To install:

Click image to see an enlarged view

Fig. Tighten the intake manifold bolts in the sequence shown-2.0L engine

  1. Install or connect the following:

    New gasket
    Intake manifold. Torque the bolts, in sequence, to 13 ft. lbs. (18 Nm).
    Alternator
    KS electrical connector
    PCV vacuum line
    4 vacuum lines
    Brake booster vacuum supply hose
    PCM wire harness to the bracket
    Main engine control sensor wiring
    IAC valve electrical connector and attach the harness to the bracket
    TP sensor electrical connector
    Fuel injection supply manifold
    Negative battery cable

  2. Start the vehicle and check for leaks, repair if necessary.

2.3L Engine
Except Hybrid
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. With the vehicle in NEUTRAL, position it on a hoist.
  3. Remove the throttle body.
  4. Remove the fuel rail.
  5. Remove the oil level indicator tube.
  6. Remove the vacuum tube.
  7. Remove the vacuum supply hose.
  8. Remove the fuel vapor return hose.
  9. Remove the idle air control (IAC) motor electrical connector.
  10. Remove the swirl control valve electrical connector.
  11. Remove the knock sensor (KS) electrical connector.
  12. Remove the temperature manifold absolute pressure (TMAP) sensor electrical connector.
  13. Remove the oil pressure sender electrical connector.
  14. Remove the engine control wiring harness.
  15. Remove the intake manifold bolts.
    NOTE
    There are three different size bolts used. Mark the location of the bolts to make sure they are installed in the correct location.



    Click image to see an enlarged view

    Fig. Intake manifold and related parts-2.3L engine, exc. Hybrid



    Click image to see an enlarged view

    Fig. Intake manifold installation-2.3L engine, exc. Hybrid

  16. Remove the bolts and position the intake manifold aside to access the crankcase vent hose clamp and the EGR tube.
  17. Remove the crankcase vent hose.
  18. Remove the exhaust gas recirculation (EGR) tube.
  19. Remove the intake manifold.
  20. Remove the intake manifold gasket.
  21. To install, reverse the removal procedure. Torque the intake manifold bolts to 13 ft. lbs. (18 Nm).

Hybrid


Click image to see an enlarged view

Fig. Intake manifold and related parts-2.3L Hybrid engine



Click image to see an enlarged view

Fig. Intake manifold installation-2.3L Hybrid engine



Click image to see an enlarged view

Fig. Throttle body-2.3L Hybrid engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2. With vehicle in NEUTRAL, position it on a hoist.
  3. Remove the throttle body.
  4. Remove the fuel rail.
  5. Loosen the clamp and disconnect the secondary air injection (AIR) tube from the AIR pump hose.
  6. Remove the right and left splash shields.
  7. Remove the 2 bolts and position the motor electronics coolant pump aside.
  8. Disconnect the AIR pump electrical connector.
  9. Remove the 2 bolts and the AIR pump.
  10. Remove the 5 bolts and the right splash shield.
  11. Remove the lower oil level indicator tube bolt.
  12. Remove the oil level indictor.
  13. Remove the upper bolt and the oil level indicator tube.
  14. Remove and discard the oil level indicator tube O-ring seal.
  15. Disconnect the oil pressure sender electrical connector.
  16. Disconnect the TMAP sensor electrical connector.
  17. Disconnect the swirl control valve electrical connector.
  18. Disconnect the IMRC actuator electrical connector.
  19. If equipped, disconnect the block heater electrical harness connector.
  20. Disconnect the KS electrical connector and detach the pin-type retainer.
  21. Disconnect the fuel vapor return hose from the intake manifold.
  22. Disconnect the power brake booster vacuum tube. Depress the quick release locking ring. Pull the vacuum tube out of the quick release fitting.
    NOTE
    There are 3 different size bolts used. Mark the location of the bolts to make sure they are installed in the correct location.

  23. Remove the 8 bolts and position the intake manifold aside to access the crankcase vent hose clamp and the EGR tube.
  24. Release the clamp and disconnect the crankcase vent hose.
  25. Remove the EGR tube.
  26. Remove the intake manifold and gaskets.
  27. To install, reverse the removal procedure. Inspect and install new intake manifold gaskets if necessary. Observe the following torques:

    EGR tube: 41 ft. lbs. (55 Nm)
    Intake manifold: 13 ft. lbs. (18 Nm)
    Upper oil level indicator tube bolt: 89 inch lbs. (10 Nm)
    Lower oil level indicator tube bolt: 35 ft. lbs. (47 Nm)
    AIR pump: 22 ft. lbs. (30 Nm)
    Motor electronics coolant pump: 62 inch lbs. (7 Nm)


3.0L Engine
Lower Manifold
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Properly relieve the fuel system pressure.
  3. Remove or disconnect the following:

    Negative battery cable
    Fuel line spring lock coupling
    Upper intake manifold
    Fuel rail
    Fuel injector electrical connectors
    Fuel pressure damper vacuum line
    Lower intake manifold
    Lower intake manifold from the fuel rail
    Fuel injectors from the manifold and discard the gasket

  4. Clean the mating surfaces.

To install:

Click image to see an enlarged view

Fig. Tighten the lower intake manifold bolts in the sequence shown-3.0L engine

  1. Inspect the fuel injector O-rings and replace if necessary.
  2. Install or connect the following:

    Fuel injectors into the lower intake manifold
    Fuel rail. Torque the bolts to 89 inch lbs. (10 Nm).
    New gasket
    Intake manifold. Torque the bolts, in sequence, to 89 inch lbs. (10 Nm).
    Fuel rail electrical connectors
    Fuel injector electrical connectors
    Fuel pressure damper vacuum line
    Upper intake manifold
    Fuel line spring lock coupling
    Negative battery cable

  3. Start the vehicle and check for leaks, repair if necessary.

Upper Manifold
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Properly relieve the fuel system pressure.
  3. Drain the coolant system.
  4. Remove or disconnect the following:

    Negative battery cable
    Air cleaner outlet tube
    Engine appearance cover
    Throttle cable
    Speed control cable, if equipped
    Throttle cable bracket
    Throttle Position (TP) sensor electrical connector
    Idle Air Control (IAC) valve electrical connector
    Exhaust Gas Recirculation (EGR) valve vacuum hose and tube
    EGR vacuum regulator valve electrical connector and hose
    Chassis vacuum hose
    Engine vacuum hose
    Positive Crankcase Ventilation (PCV) hose
    Vapor Management Valve (VMV) vacuum hose
    Electrical connectors from the left side of the upper intake manifold
    Power Steering Pressure (PSP) sensor electrical connector
    Upper intake manifold and discard the gasket

  5. Clean the mating surfaces.

To install:

Click image to see an enlarged view

Fig. Tighten the upper intake manifold bolts in the sequence shown-3.0L engine

  1. Install or connect the following:

    New gasket
    Intake manifold. Torque the bolts, in sequence, to 89 inch lbs. (10 Nm).
    PSP electrical connector
    Electrical connectors on the left side of the upper intake manifold
    VMV vacuum hose
    Chassis, engine and PCV hoses
    EGR valve vacuum regulator
    EGR valve vacuum hose and tube. Torque the nut to 30 ft. lbs. (40 Nm).
    TP sensor electrical connector
    IAC valve electrical connector
    Throttle cable and speed control cable, if equipped. Torque the bracket bolts to 89 inch lbs. (10 Nm).
    Air cleaner outlet tube
    Engine appearance cover. Torque the bolts to 53 inch lbs. (6 Nm).
    Negative battery cable

  2. Fill the coolant system to the proper level.
  3. Start the vehicle and check for leaks, repair if necessary.
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Rear Main Seal



Removal & Installation



2.0L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove or disconnect the following:

    Negative battery cable
    Flywheel
    Rear main seal

    Click image to see an enlarged view

    Fig. Rear main seal removal-2.0L engine



To install:

  1. Coat the oil seal with clean engine oil.
  2. Install or connect the following:

    Crankshaft rear oil seal
    Flywheel
    Negative battery cable


2.3L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. With the vehicle in NEUTRAL, position it on a hoist.
  3. If equipped, remove the automatic transaxle.
  4. If equipped, remove the manual transaxle and clutch.
  5. Remove the flexplate or flywheel.
  6. Remove the oil pan.
  7. Remove the crankshaft rear oil seal with retainer plate

    Click image to see an enlarged view

    Fig. Rear main seal and related parts-2.3L engine


To install:

  1. Using a seal installer, position the crankshaft rear oil seal with retainer plate onto the crankshaft.
  2. Install the crankshaft rear oil seal with retainer plate. Tighten the bolts in the sequence shown to 89 inch lbs. (10 Nm).
  3. Install the oil pan.
    NOTE
    Special bolts are used for installation. Do not use standard bolts.



    Click image to see an enlarged view

    Fig. Retainer plate torque sequence-2.3L engine



    Click image to see an enlarged view

    Fig. Flywheel torque sequence-2.3L engine

  4. Install the flywheel/flexplate. Tighten the bolts in the sequence shown in three stages.
    1. Stage 1: Tighten to 37 ft. lbs. (50 Nm).
    2. Stage 2: Tighten to 50 ft. lbs. (80 Nm).
    3. Stage 3: Tighten to 83 ft. lbs. (112 Nm).


3.0L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove or disconnect the following:

    Negative battery cable
    Flexplate
    Rear main oil seal

    Click image to see an enlarged view

    Fig. Rear main seal removal-3.0L engine



To install:

Click image to see an enlarged view

Fig. Rear main seal installation-3.0L engine

  1. Coat the oil seal with clean engine oil.
  2. Install or connect the following:

    Crankshaft rear oil seal
    Flywheel
    Negative battery cable

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Also for left exhaust manifold, click this link:---

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for right exhaust manifold, click this link:---
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