For replacing the intake manifold gasket on a 1.6L Duratec Ti-VCT engine perform the following operations.
You will need: TORX T25 key, 10 mm socket head, flat-blade screwdriver.
1. Reduce the pressure in the fuel system (see Reducing pressure in the engine fuel system).
2. Disconnect the wire from the negative terminal of the battery.
3. Remove the air supply hose (see Removing and installing the air filter and intake silencer).
4. Remove the crankcase ventilation pipe (see Cleaning the crankcase ventilation system).
5. Disconnect the fuel supply line from the fuel rail, remove the injector electrical connector rail and the fuel rail (see Removing and installing the fuel rail).
6. Remove the screw securing the oil level indicator bracket.
7. Disconnect the brake booster and purge valve hoses from the intake pipe.
8. Slide the lock up…
9….and disconnect the wiring harness connector from the throttle body cover.
Fig. 5.35. Intake pipe mounting bolts.
10. Unscrew the seven bolts securing the intake pipe (Fig. 5.35), and then remove it together with the throttle assembly and the gasket installed underneath it.
11. Install the intake manifold with a new gasket. Tighten the mounting bolts evenly crosswise to a torque of 15 N·m (1.5 kgf·m), starting with the outer bolts and moving to the middle ones.
12. Install all removed parts in the reverse order of removal. When installing the fuel rail, use new fuel injector sealing rings.
For replacing the intake manifold gasket of 2.0L and 2.3L Duratec-HE engines perform the following operations.
You will need: TORX T25 key, 10 mm socket head, flat-blade screwdriver.
1. Reduce the pressure in the fuel system (see Reducing pressure in the engine fuel system).
2. Disconnect the wire from the negative terminal of the battery.
3. Remove the air supply hose (see Removing and installing the air filter and intake silencer).
4. Slide the lock…
5….and disconnect the wiring harness connector from the throttle body cover.
6. Disconnect the fuel line from the fuel rail (see Removing and installing the fuel rail).
7. Disconnect the purge hose from the intake pipe fitting.
8. Remove the screw securing the oil level indicator bracket.
9. Remove the intake pipe mounting bolts…
NOTE: This is the location of the intake manifold mounting bolts.
10….and remove the intake pipe assembly with the throttle assembly.
11. Remove the old gaskets.
12. Install the intake manifold with new gaskets. Tighten the mounting bolts evenly crosswise to a torque of 15 N·m (1.5 kgf·m), starting with the outer bolts and moving to the middle ones.
13. Install all removed parts in the reverse order of removal. When installing the fuel rail, use new fuel injector sealing rings.