Friday, March 16, 2012

How To Replace Exhaust Manifold On Ford Ranger?

Exhaust Manifold Replacing for Ford Ranger:----


Exhaust Manifold
REMOVAL & INSTALLATION Details are mentioned below:----

3.0L Engine
Left Side
Specific to:
Ford Ranger 2008
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. With the vehicle in NEUTRAL, position it on a hoist.
  3. Disconnect the battery ground cable.
  4. Remove the exhaust flange nuts.
  5. Remove the nut and the oil level indicator and tube assembly.
  6. Remove the nut and the upper intake manifold support brace.
  7. Detach the exhaust manifold-to-EGR valve tube from the exhaust manifold.
  8. Remove the bolts, stud bolts, exhaust manifold and gasket.
  9. Clean and inspect the exhaust manifold. 

    image
    Fig. Left exhaust manifold-3.0L engine
To install:

NOTE
Install a new exhaust manifold gasket, bolts and stud bolts.

  1. Install the exhaust manifold gasket, exhaust manifold, bolts and stud bolts.
  2. Tighten in the sequence shown in 2 stages:

    Stage 1: Tighten to 89 inch lbs. (10 Nm).
    Stage 2: Tighten to 17 ft. lbs. (23 Nm).

    Click image to see an enlarged view
    Fig. Left exhaust manifold tightening sequence-3.0L engine
  3. Attach the exhaust manifold-to-EGR valve tube to the exhaust manifold. Tighten to 37 ft. lbs. (50 Nm).
  4. Install the upper intake manifold support brace and nut. Tighten to 62 inch lbs. (7 Nm).
    NOTE
    The end of the oil level indicator tube should be cleaned with metal surface prep before application of the sealant.
  5. Install the oil level indicator and tube assembly. Coat the oil level indicator tube with silicone gasket and sealant
  6. Install the oil level indicator tube bracket nut and tighten to 13 ft. lbs. (18 Nm).
  7. Install the exhaust flange nuts and tighten to 30 ft. lbs. (40 Nm).
  8. Connect the battery ground cable.
  9. Start the engine and check for leaks, repair if necessary.
Right Side
Specific to:
Ford Ranger 2008
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. With the vehicle in NEUTRAL, position it on a hoist.
  3. Disconnect the negative battery cable.
  4. Remove the exhaust flange nuts.
  5. Remove the bolts, stud bolts, exhaust manifold and gasket. Discard the bolts, stud bolts and exhaust manifold gasket.
  6. Clean and inspect the exhaust manifold.

    Click image to see an enlarged view
    Fig. Right exhaust manifold-3.0L engine
To install:

NOTE
Install a new exhaust manifold gasket, bolts and stud bolts.

  1. Install the exhaust manifold gasket, exhaust manifold, bolts and stud bolts.
  2. Tighten in the sequence shown in 2 stages:

    Stage 1: Tighten to 89 inch lbs. (10 Nm).
    Stage 2: Tighten to 17 ft. lbs. (23 Nm).

    Click image to see an enlarged view
    Fig. Right exhaust manifold tightening sequence-3.0L engine
  3. Install the exhaust flange nuts.
  4. Connect the negative battery cable.
  5. Start the engine and check for leaks, repair if necessary.
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. Disconnect the battery ground cable.
  4. Remove the accessory drive belt.
  5. Drain the engine cooling system.
  6. Remove the 2 exhaust downpipe flange nuts.
  7. Disconnect the upper radiator hose and the degas bottle coolant hose from the front coolant outlet pipe.
  8. If equipped, remove the A/C compressor.
  9. Disconnect the heater coolant hose from the front coolant outlet pipe.
  10. Remove the oil level indicator, the 2 bolts and the oil level indicator tube. Discard the O-ring seal.
  11. Remove the 2 bolts and the front coolant outlet pipe. Discard the O-ring seal.

    Click image to see an enlarged view
    Fig. Remove the 2 bolts and the front coolant outlet pipe
  12. Remove the 5 pushpins and position the right inner fender splash shield aside.
  13. Disconnect the generator electrical connections.
  14. Remove the 5 bolts and the generator and support bracket assembly.
  15. Remove the 2 nuts and position the coolant tube aside.
  16. Remove the 7 nuts, the exhaust manifold and the gasket. Discard the exhaust manifold nuts and the gasket.
  17. Remove and discard the 7 exhaust manifold-to-cylinder head studs.
  18. Clean and inspect the exhaust manifold.

    Click image to see an enlarged view
    Fig. Exhaust manifold-2.3L engine
To install:
  1. Install 7 new exhaust manifold-to-cylinder head studs and tighten to 150 inch lbs. (17 Nm).
  2. Install a new exhaust manifold gasket.
  3. Position the exhaust manifold and install 7 new nuts. Tighten the nuts to 40 ft. lbs. (54 Nm).
  4. Position the coolant tube and install the 2 nuts. Tighten the nuts to 40 177 inch lbs. (20 Nm).
  5. Position the alternator and support bracket assembly and install the 5 bolts in the sequence shown, in 2 stages:

    Stage 1: Install finger-tight.
    Stage 2: Tighten to 35 ft. lbs. (47 Nm).

    Click image to see an enlarged view
    Fig. Alternator support bracket tightening sequence
  6. Connect the generator electrical connections. Tighten the battery cable nut to 71 inch lbs. (8 Nm).
  7. Position the right inner splash shield and install the 5 pushpins.
    NOTE
    Lubricate the new O-ring seal with clean engine coolant prior to installation.
  8. Using a new O-ring seal, position the front coolant outlet pipe and install the 2 bolts. Tighten to 18 ft. lbs. (25 Nm).
  9. Lubricate the new O-ring seal with clean engine oil prior to installation.
  10. Using a new O-ring seal, position the oil level indicator tube assembly and install the 2 bolts. Tighten to 89 inch lbs. (10 Nm).
  11. Install the oil level indicator.
  12. Connect the heater coolant hose to the front coolant outlet pipe.
  13. If equipped, install the A/C compressor.
  14. Connect the upper radiator hose and the degas bottle coolant hose to the front coolant outlet pipe.
  15. Install the 2 exhaust downpipe flange nuts and tighten to 30 ft. lbs. (40 Nm).
  16. Install the accessory drive belt.
  17. Connect the battery ground cable.
  18. Fill and bleed the engine cooling system.
  19. Start the engine and check for leaks, repair if necessary.
4.0L Engine
Left Side
Specific to:
Ford Ranger 2008-2009
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect the negative battery cable.
  3. With the vehicle in NEUTRAL, position it on a hoist.
  4. Detach the differential feedback pressure EGR sensor from the exhaust manifold-to-EGR valve tube.
  5. Remove the exhaust manifold-to-EGR valve tube.
  6. Remove the 2 exhaust manifold-to-dual converter Y-pipe nuts.
  7. Remove the 6 nuts, the LH exhaust manifold and the gasket. Discard the nuts and the gasket.
  8. Remove and discard the 6 LH exhaust manifold studs.

    Click image to see an enlarged view
    Fig. Left exhaust manifold-4.0L engine
To install:
  1. Clean and inspect the LH exhaust manifold.
  2. Install 6 new LH exhaust manifold studs and tighten to 106 inch lbs. (12 Nm).
  3. Position a new gasket and the exhaust manifold and install 6 new nuts. Tighten to 16 ft. lbs. (22 Nm).
  4. Position the dual converter Y-pipe and install the 2 nuts. Tighten to 30 ft. lbs. (40 Nm).
  5. Install the exhaust manifold-to-EGR valve tube and tighten to 25 ft. lbs. (34 Nm).
  6. Attach the differential pressure feedback EGR sensor to the exhaust manifold-to-EGR valve tube.
  7. Connect the negative battery cable.
  8. Start the engine and check for leaks, repair if necessary.
Right Side
Specific to:
Ford Ranger 2008-2009
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect the negative battery cable.
  3. With the vehicle in NEUTRAL, position it on a hoist.
  4. Remove the 2 exhaust manifold-to-dual converter Y-pipe nuts.
  5. Remove the 6 nuts, the RH exhaust manifold and the gasket. Discard the nuts and the gasket.
  6. Remove and discard the 6 RH exhaust manifold studs.

    Click image to see an enlarged view
    Fig. Right exhaust manifold-4.0L engine
To install:
  1. Clean and inspect the RH exhaust manifold.
  2. Install 6 new LH exhaust manifold studs and tighten to 106 inch lbs. (12 Nm).Position a new gasket and the RH exhaust manifold and install 6 new nuts. Tighten to 16 ft. lbs. (22 Nm).
  3. Position the dual converter Y-pipe and install the 2 nuts. Tighten to 30 ft. lbs. (40 Nm).
  4. Connect the negative battery cable.
  5. Start the engine and check for leaks, repair if necessary.

These details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

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



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