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How to Replace the Exhaust Manifold in a Mercury Cougar

Mercury discontinued the Cougar in 2002. Introduced in 1967, the Cougar evolved from a "pony car" to a roomy, personal luxury coupe linked only to the original by the Ford label. A 2.0L engine was standard in the base model of the Cougar from 2000 to the final issue in 2002. An experienced do-it-yourself mechanic can take on the installation of the exhaust manifold.



Difficulty: ChallengingInstructions
    Remove the Exhaust Manifold
  1. Step 1

    Disconnect the negative battery cable and remove the air intake resonators. Take out the oil dipstick tube and the exhaust manifold heat shield.

  2. Step 2

    Remove the heated oxygen sensor and the Exhaust Gas Recirculation (EGR) tube and its bracket. Remove the catalytic converter.

  3. Step 3

    Loosen the nine retaining nuts and then remove them. Separate the exhaust manifold from the engine.

  4. Step 4

    Clean the mating surfaces to remove any gasket material, dirt and carbon deposits. Wipe the surfaces clean with solvent and check for damage.

    5. Install the Exhaust Manifold
  5. Step 1

    Install the new gasket to the cylinder head. Align the exhaust manifold over the gasket and set the nuts in place.

  6. Step 2

    Tighten the nuts in sequence, working out from the center. Torque the nuts to 12 foot pounds.

  7. Step 3

    Set the catalytic converter in place and secure it. Connected the EGR rube and bracket.

  8. Step 4

    Connect the oxygen sensor. Set the exhaust manifold heat shield in place.

  9. Step 5

    Replace the oil dipstick tube and the air intake resonators. Reconnect the negative battery cable.

  10. Step 6

    Start the engine and allow it to warm up for several minutes. Check for exhaust leaks and proper operation.

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Pre：How to Replace the Exhaust Manifold in a Mazda6   Next：How to Replace the Intake Manifold in a Mercury Villager

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