Ford Mondeo exhaust manifold removal, inspection and refitting - is a part of Ford Mondeo repair manuals: Engines. This part contains the detailed description of engine repair procedures and engine diagrams for Ford Mondeo with four-cylinder petrol engines, including special/limited editions (1597cc, 1796cc, 1988cc), Diesel and V6 engines.
Ford Mondeo exhaust manifold removal:
- disconnect the battery negative (earth) lead;
- unbolt the resonator support bracket from the engine compartment front crossmember, slacken the two clamp screws securing the resonator to the air mass meter and plenum chamber hoses, then swing the resonator up clear of the thermostat housing;
- drain the cooling system;
- disconnect the coolant hose and the coolant pipe/hose from the thermostat housing; secure them clear of the working area;
- unbolt the exhaust manifold heat shield, and withdraw both parts of the shield; apply penetrating oil to the EGR pipe sleeve nut, and to the exhaust manifold mounting nuts (also to the pulse-air system sleeve nuts, if they are to be unscrewed);
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- unscrew the sleeve nut securing the EGR pipe to the manifold, remove the two screws securing the pipe to the ignition coil bracket, then slacken the sleeve nut securing the pipe to the EGR valve;
- while the manifold can be removed with the pulse-air system components attached -unbolt the filter housing and disconnect its vacuum hose if this is to be done - it is easier to remove the pulse-air assembly first;
- unplugging the oxygen sensor electrical connector to avoid straining its wiring, unscrew the nuts to disconnect the exhaust system front downpipe from the manifold;
- remove the nuts and detach the manifold and gasket; take care not to damage vulnerable components such as the EGR pipe as the manifold assembly is manoeuvred out of the engine compartment; when removing the manifold with the engine in the vehicle, additional clearance can be obtained by unscrewing the studs from the cylinder head; a female Torx-type socket will be required;
Ford Mondeo exhaust manifold inspection:
- use a scraper to remove all traces of old gasket material and carbon deposits from the manifold and cylinder head mating surfaces; if the gasket was leaking, have the manifold checked for warpage at an automotive machine shop, and have it resurfaced if necessary;
- provided both mating surfaces are clean and flat, a new gasket will be sufficient to ensure the joint is gas-tight; do not use any kind of exhaust sealant upstream of the catalytic converter;
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- note that the downpipe is secured to the manifold by two bolts, with a coil spring, spring seat and self-locking nut on each; on refitting, tighten the nuts until they stop on the bolt shoulders; the pressure of the springs will then suffice to make a leakproof joint;
- do not overtighten the nuts to cure a leak - the bolts will shear; renew the gasket and the springs if a leak is found; the bolts themselves are secured by spring clips to the manifold, and can be renewed easily if damaged.
Ford Mondeo exhaust manifold refitting:
- refitting is the reverse of the removal procedure, noting the following points: position a new gasket over the cylinder head studs, and fit a new plastic guide sleeve to the stud nearest to the thermostat housing, so that the manifold will be correctly located; do not refit the manifold without this sleeve; refit the manifold, and finger-tighten the mounting nuts; working from the centre out, and in three or four equal steps, tighten the nuts to the torque wrench setting given in Ford Mondeo repair manuals: Engines - Specifications; refit the remaining parts in the reverse order of removal; tighten all fasteners to the specified torque wrench settings; refill the cooling system; run the engine, and check for exhaust leaks; check the coolant level when fully warmed-up to normal operating temperature.
from Ford Mondeo repair manuals
