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:

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:

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:

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

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:
    
    
    

    

    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

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.
   
   
   

   

   Fig. Intake manifold bolt loosening sequence-2.0L engine

To install:

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.
    
    
    
    
    

    

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

    
    
    
    

    

    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

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

Fig. Intake manifold installation-2.3L Hybrid engine

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:

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:

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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