Here's a general overview of the process. Remember that specifics will vary depending on the year and engine of your Aspire:
1. Preparation:
* Safety First: Disconnect the negative battery terminal to prevent electrical shorts. Wear safety glasses and gloves. Work in a well-ventilated area.
* Gather Tools: You'll need various wrenches (likely metric), sockets, a ratchet, possibly a breaker bar for stubborn bolts, penetrating oil (like PB Blaster), jack stands, jack, and possibly an exhaust manifold gasket. A torque wrench is highly recommended for proper tightening.
* Consult a Repair Manual: Obtain a repair manual specific to your Ford Aspire's year and engine. This manual will provide precise torque specifications, bolt locations, and diagrams crucial for successful installation.
2. Removal of the Old Manifold (if applicable):
* Access: You'll likely need to jack up the car and securely support it with jack stands for sufficient access. Consult your repair manual for proper jack points.
* Disconnect Components: Disconnect any connected components, such as the exhaust pipe, oxygen sensor(s), and any heat shields. Take photos as you go to aid in reassembly.
* Loosen Bolts: Apply penetrating oil to the manifold bolts and allow sufficient time for it to soak in. Carefully loosen the bolts securing the manifold to the engine block. These bolts can be very stubborn due to heat and rust.
* Removal: Once all bolts are loose, carefully remove the old manifold. Be aware of sharp edges and potential hot spots.
3. Installation of the New Manifold:
* Clean Surfaces: Clean the engine block mating surfaces where the manifold will sit. Any debris can prevent a proper seal.
* Gasket: Install a new exhaust manifold gasket (if necessary; check your repair manual). Ensure it's properly seated.
* Position Manifold: Carefully position the new exhaust manifold onto the engine block, aligning the bolt holes.
* Tighten Bolts: Tighten the manifold bolts in a crisscross pattern, gradually tightening each bolt a little at a time. Do not overtighten. Refer to your repair manual for the correct torque specifications.
* Reconnect Components: Reconnect all the components you disconnected earlier (exhaust pipe, oxygen sensor(s), heat shields).
4. Post-Installation:
* Check for Leaks: After everything is reconnected, start the engine and carefully inspect the manifold and connections for any leaks. Listen for unusual exhaust noises.
* Torque Check: After running the engine for a short period, re-check the manifold bolt tightness.
* Lower Vehicle: Carefully lower the vehicle from the jack stands.
Important Considerations:
* Rust and Corrosion: Older Aspires are prone to rust and corrosion. Expect challenging bolt removal. Consider using a heat gun (carefully!) to help loosen stubborn bolts.
* Exhaust System: Be aware of the entire exhaust system. You may need to loosen other components to maneuver the manifold.
* Engine Coolant: Be cautious of potential coolant leaks during this process.
This is a simplified overview. Consult a repair manual specific to your Ford Aspire for detailed instructions, torque specifications, and diagrams. If you're unsure about any step, seek professional help. Improper installation can lead to exhaust leaks, engine damage, and even safety hazards.
