This procedure covers the removal and replacement of the exhaust manifold on a 2011-2014 Ford F-150 with the 3.5L EcoBoost V6 engine, including turbocharger and exhaust component removal.

Warnings

Tools required

Parts

• Exhaust manifold gasket × 1 — Use OEM specification
• Turbocharger to exhaust manifold gasket × 1 — Use OEM specification
• Exhaust flange gasket × 1 — Use OEM specification
• O2 sensor (if damaged) × 1 — Use OEM specification

Fluids

• Motorcraft Orange Coolant — 2 qt

Preparation

1. Ensure engine is completely cold (wait at least 4 hours after last operation)
2. Disconnect negative battery cable
3. Raise and support vehicle on jack stands at appropriate lift points
4. Remove engine splash shield and undercarriage panels for access
5. Apply penetrating oil to all exhaust manifold nuts, flange bolts, and O2 sensor threads
6. Drain approximately 2 quarts of coolant from radiator to reduce spillage during intercooler removal

Procedure

1. 1

   Remove charge air cooler and intercooler components
   Remove the charge air cooler inlet and outlet tubes. Disconnect clamps and loosen hose connections. Remove the intercooler assembly to gain access to the turbocharger and exhaust manifold. Note the routing of all hoses and tubes for reinstallation.
2. 2

   Disconnect oxygen sensors
   Locate the upstream O2 sensor on the exhaust manifold. Disconnect the electrical connector. Using an O2 sensor socket, carefully remove the sensor. If the sensor is seized, apply heat and additional penetrating oil. Inspect sensor condition and replace if damaged or heavily carboned.
   ⚠O2 sensor threads are fragile. Do not force or use excessive leverage. If sensor breaks, the manifold may require stud extraction.
   Torque spec

   O2 Sensor55 Nm (40 lb-ft)
3. 3

   Remove heat shields
   Remove the exhaust manifold heat shields. These are typically held by small bolts that may be corroded. Work carefully to avoid breaking bolts. If bolts break, they must be extracted before manifold removal.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
4. 4

   Disconnect turbocharger oil feed and drain lines
   Locate the oil feed line at the top of the turbocharger and the oil drain line at the bottom. Disconnect both lines carefully, noting orientation and routing. Cap or plug all openings immediately to prevent contamination. Expect some residual oil drainage.
   ℹ️Have shop towels ready to catch residual oil from turbocharger lines.
5. 5

   Remove turbocharger to manifold mounting
   Disconnect the turbocharger from the exhaust manifold. Remove the mounting bolts/nuts securing the turbocharger to the manifold. The turbocharger may remain in the vehicle or be removed with the manifold depending on access. Support the turbocharger weight to prevent damage to oil lines.
   Torque spec

   Mounting Bolts55 Nm (40 lb-ft)
6. 6

   Disconnect exhaust downpipe
   From underneath the vehicle, locate the exhaust flange connection between the turbocharger outlet and the exhaust downpipe. Remove the flange bolts. Separate the connection and support the exhaust system weight to prevent strain on hangers.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
7. 7

   Remove coolant lines if applicable
   If equipped, disconnect any coolant lines routed near or attached to components blocking manifold access. This may include heater hoses or coolant bypass tubes depending on the specific manifold side being serviced.
8. 8

   Remove exhaust manifold mounting nuts
   Working from the hot side (closest to turbocharger) toward the cold side, carefully remove all exhaust manifold mounting nuts. There are typically 6 nuts per manifold. Work slowly and apply penetrating oil if nuts are tight. If a stud breaks, mark its location for extraction.
   ⚠Manifold studs commonly break on EcoBoost engines. If a stud breaks flush or below the cylinder head surface, professional extraction or cylinder head removal may be required.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
9. 9

   Remove exhaust manifold
   Carefully work the exhaust manifold away from the cylinder head. The manifold may be stuck due to carbon buildup. Use gentle prying if necessary but avoid damaging the cylinder head sealing surface. Remove the old gasket material completely from both the manifold and cylinder head using a gasket scraper. Inspect the manifold for cracks or warping.
10. 10

    Inspect and prepare mating surfaces
    Thoroughly clean all gasket surfaces on the cylinder head and exhaust manifold. Remove all carbon deposits, old gasket material, and debris. Inspect cylinder head surface for damage or irregularities. Check all studs for damage and replace any that are stripped or broken. Chase threads with a thread chaser if needed.
    ⚠Do not use aggressive abrasives on aluminum cylinder head surfaces. Use plastic scrapers or soft wire brushes only.
11. 11

    Install new exhaust manifold gasket
    Position the new exhaust manifold gasket onto the cylinder head studs. Ensure the gasket is oriented correctly with any alignment features properly seated. Do not use additional sealant unless specified by the gasket manufacturer.
12. 12

    Install exhaust manifold
    Carefully position the exhaust manifold onto the studs and align with the gasket. Start all manifold nuts by hand to ensure proper thread engagement. Apply anti-seize compound to the nut threads as specified. Once all nuts are hand-started, torque in the proper sequence working from hot to cold side.
    ℹ️Torque sequence is critical. Consult factory service manual for the specific tightening pattern to ensure even gasket compression and prevent warping.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)
13. 13

    Reinstall turbocharger connection
    Install a new turbocharger to manifold gasket. Reconnect the turbocharger to the exhaust manifold using new hardware if available. Apply anti-seize to bolt threads and torque to specification. Reconnect oil feed and drain lines with new crush washers or seals.
    Torque spec

    Mounting Bolts55 Nm (40 lb-ft)
14. 14

    Reconnect exhaust downpipe
    Install new exhaust flange gasket. Reconnect the exhaust downpipe to the turbocharger outlet. Apply anti-seize to flange bolt threads and torque in a cross pattern to ensure even gasket compression.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
15. 15

    Install oxygen sensor and heat shields
    Apply anti-seize compound to O2 sensor threads (avoid getting compound on the sensor tip). Install O2 sensor and torque to specification. Reinstall heat shields and torque shield bolts following the proper sequence.
    Torque spec

    O2 Sensor55 Nm (40 lb-ft)

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Reinstall all intercooler components, charge air cooler tubes, and hoses in reverse order of removal
2. Ensure all clamps are properly tightened and hoses are correctly routed
3. Refill cooling system with Motorcraft Orange Coolant and bleed air from system
4. Reinstall engine splash shields and undercarriage panels
5. Reconnect negative battery cable
6. Double-check all connections, ensuring no tools or parts are left in engine bay

Verification

• Start engine and allow to idle. Listen for exhaust leaks at manifold, turbocharger connections, and downpipe flange
• Check for oil leaks at turbocharger feed and drain line connections
• Monitor coolant level and check for leaks around any disturbed coolant connections
• Verify no check engine lights or fault codes are present
• Perform a test drive at various loads and listen for any unusual exhaust noise or boost leaks
• Re-inspect all connections after engine reaches operating temperature and cools down
• Check exhaust manifold nuts for proper torque after first heat cycle (optional but recommended)

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