Repair 7

How to Change the Exhaust Manifold on a Ford Powerstroke Diesel

Power Stroke engines appear in heavy Ford trucks manufactured since 1994. They use diesel fuel and typically have a turbocharger. The first Power Stroke engine had a displacement of 7.3 liters and was in production from 1994 to 2003. The exhaust manifold collects the exhaust gases from the cylinders, and each side of the engine typically has its own exhaust manifold. The most common reason for replacing the exhaust manifold is rust caused by the exhaust gases.

Instructions

1

Remove the cables from the negative terminals of both batteries with a socket wrench. This prevents anyone from accidentally starting the engine while you are replacing the exhaust manifold.

2

Access the right exhaust manifold from the top of the engine compartment. Bend the tabs on the attaching bolts for the right exhaust manifold, and disconnect the inlet pipe of the right muffler from the right exhaust manifold with a socket wrench.

3

Raise the vehicle and support it on jack stands. Access the left exhaust manifold from underneath the vehicle, and bend the tabs on the attaching bolts for the left exhaust manifold. Disconnect the inlet pipe of the left muffler from the left exhaust manifold with a socket wrench.

4

Clean the cylinder heads with a shop towel, and apply anti-seize compound to the threads on the new exhaust manifolds. Connect the new left exhaust manifold with a new gasket and locking tabs. Tighten the mounting bolts for the left exhaust manifold to 45 foot-pounds with a torque wrench. Bend the locking tabs over the bolt heads to secure the bolts.

5

Lower the vehicle and connect the new right exhaust manifold with a new gasket and locking tabs. Tighten the mounting bolts for the right exhaust manifold to 45 foot-pounds with a torque wrench. Bend the locking tabs over the bolt heads to secure the bolts.

6

Connect the cable to the negative terminal for both batteries with a socket wrench. Start the engine and correct any leaks in the exhaust system.