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Cast-iron exhaust manifold with rusty outlet pipe on an EFI engi…

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Rusty exhaust manifold outlet and brackets in a dirty engine bay

Rusty 4.9L Ford exhaust manifold on concrete with overlaid labels

Rusty cast-iron 4.9L Ford exhaust manifold on concrete floor

Rusty exhaust manifold in a bench vise with torch tip and PB Blaster penetrant during stud removal

Engine cylinder head with exhaust manifold removed, showing three open exhaust ports and rusty surfaces

Custom welded steel vault door with keyed lock, shown closed and open

Hand spraying water to clean a car carpet hung on a red fence outdoors

Metal locked vault box on the trunk of a tan Ford Crown Victoria sedan

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Apparently, these Dorman manifolds are also compatible with the '96-only oxygen sensors. I anti-siezed the plugs & reinstalled them tightly. I removed the EGR plug & installed the flare fitting and studs, also with anti-seize. The flange cones & head mating surfaces are coated with chassis grease.

This pic also shows where I spliced the '94-97 evaporator inlet (R-134a orifice tube) to the '93 evaporator so I could use the corresponding parallel-flow condenser & hard Aluminum liquid line. Since the splice is on the low-pressure side of the orifice, the highest pressure it should ever see is when the A/C is off (~100psi).

Later, I cup-brushed the alt/smog bracket mounting points (for electrical contact) and reinstalled it withOUT the lower 1/2" bolt (just behind the bottom of the WP pulley) since that one is such a PITA to access, and largely unnecessary.