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.

Instructions

Remove the Exhaust Manifold

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

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

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

Install the Exhaust Manifold

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

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

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

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

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

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