Exhaust Manifold(S) Removal And Refitting - Ford Scorpio Owner's Manual

40.59 Removing a spark plug spacer from
the cylinder head recess
55 Release the throttle position sensor wiring
connector from the clip under the throttle
body, and separate the two halves of the
connector.
56 Remove the fuel-injectors.
57 Check that all relevant wiring, hoses and
pipes have been disconnected to facilitate
removal of the manifold.
58 Unscrew the ten bolts and two nuts
securing the inlet manifold to the cylinder
head, and carefully withdraw the manifold.
Recover the gasket.
59 Recover the two plastic spark plug
spacers from the recesses in the cylinder head
(see illustration).
60 If desired, the manifold can be dismantled
with reference to the relevant paragraphs of
this Chapter.
61 Refitting is a reversal of removal, bearing
in mind the following points.
a) Ensure that the spark plug spacers are in
position in the cylinder head recesses
before refitting the manifold.
b) Ensure manifold and cylinder head mating
surfaces are clean and dry and fit a new
gasket.
c) Tighten the manifold retaining nuts and
bolts evenly and progressively to the
specified torque.
d) Refit the fuel-injectors.
e) Make sure that all hoses, pipes and wires
are securely reconnected in their original
positions.
f) On completion, refill the cooling system.
g) Check the adjustment of the throttle cable
and where necessary, adjust the speed
control cable so that only a small amount
of slack is present in the cable.
h) Where applicable, check and if necessary
adjust the idle speed and mixture.
V6 engines
62 Disconnect the battery negative lead.
63 Drain the cooling system.
64 Remove the throttle linkage cover.
65 Release the hose clips and move the
airflow meter-to-manifold trunking aside.
Unclip or remove the crankcase ventilation
hose.
66 Disconnect the radiator top hose and the
heater hose from the outlet at the front of the
manifold. Be prepared for some coolant spillage.
40.79 Inlet manifold bolt tightening
sequence
Arrow points to front of engine
67 Disconnect the multi-plugs from the idle
speed control valve, the temperature gauge
sender unit; the coolant temperature sensor
and the throttle position sensor. Also
disconnect the injector wiring harness.
68 Disconnect the throttle cable from the
linkage, unclip it and move it aside. On
automatic transmission models,
disconnect the downshift cable or multi-plug,
as applicable.
69 Disconnect the fuel feed and return pipes.
Be prepared for fuel spillage.
70 Remove the HT leads and the distributor.
71 Remove the plenum chamber, which is
secured by eight bolts.
72 Remove the rocker covers, which are each
secured by seven bolts.
73 Disconnect the water pump bypass hose
from the inlet manifold.
74 Remove the eight bolts which secure the
inlet manifold to the cylinder heads.
75 Lift off the manifold complete with fuel
pressure regulator, fuel rail, throttle body
housing etc. If it is stuck, carefully lever it free.
Do not apply leverage at the mating faces.
Recover the gasket.
76 Clean all mating faces, being careful to
keep dirt out of ports and other orifices.
Obtain new gaskets for both the cylinder head
and plenum chamber sides of the manifold,
and for the rocker covers.
77 Commence refitting by applying sealant
(Ford part No A70X-19554-BA, or equivalent)
around the ports and coolant passages on the
cylinder head.
78 Apply sealant around the apertures on
both sides of the gasket. then fit the gasket to
the cylinder heads.
79 Refit the manifold and insert the securing
bolts. Tighten the bolts, in the order shown
(see illustration), through the first four stages
given in the Specifications.
80 Refit the water pump bypass hose.
81 Refit the rocker covers, using new
gaskets. The adhesive sides of the gaskets
must face the covers.
82 Reverse the remaining
operations, but do not refit the throttle linkage
cover yet.
83 When the cooling system has been
Fuel and exhaust systems 4•21
40.87 Cranked spanner needed for
tightening V6 inlet manifold bolt with
distributor fitted
refilled, reconnect the battery and start the
engine. Check for fuel and other leaks.
84 Bring the engine to operating temperature,
then stop it and carry out the final tightening of
the inlet manifold bolts as follows.
85 Release the air inlet trunking. Unplug the
idle speed control valve and the throttle
position sensor. Unbolt the plenum chamber
also
and move it aside, disconnecting vacuum and
breather hoses as necessary.
86 Slacken, but do not remove, the two bolts
which secure the fuel rail to the manifold.
87 Tighten the inlet manifold bolts to the
Stage 5 specified torque, again following the
sequence shown. A special cranked spanner
(Ford tool No 21-079, or equivalent) (see
illustration) will be needed to tighten No 4
bolt when the distributor is fitted. In the
absence of such a spanner, remove the
distributor again.
88 Tighten the fuel rail securing bolts.
89 Refit the disturbed components. Run the
engine again and check the ignition timing and
the exhaust CO level .
90 Refit the throttle linkage cover.
41 Exhaust manifold(s) - removal
and refitting
SOHC and all V6 engines
1 Disconnect the battery negative lead.
2 Apply copious quantities of penetrating oil
to the manifold and exhaust pipe flange nuts
and bolts.
3 On carburettor models, remove the air
cleaner and the hot air pick-up pipe.
4 Unbolt any heat shields or shrouds from the
manifold.
5 Unbolt the exhaust pipe(s) from the manifold
flange. Support the exhaust system if
necessary.
6 Unbolt the manifold from the cylinder head
and remove it. Recover the gasket.
7 Refit by reversing the removal operations.
Use a new gasket, and apply anti-seize
removal
compound to the various nuts and bolts.
Tighten the manifold fastenings to the
specified torque.
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