Replacing the intake pipe gasket

A gasket is installed between the flanges of the cylinder head and the intake pipe. If this gasket is leaking, the engine will run unevenly ("troit"). If the problem cannot be corrected by tightening the intake pipe, replace the gasket.

To replace the intake manifold gasket on a 1.6L Duratec Ti-VCT engine, follow these steps.

You will need: TORX T25 wrench, 10 socket socket, flat blade screwdriver.

1. Reduce the pressure in the supply system (see Reducing the pressure in the engine supply system).

2. Disconnect a wire from the minus plug of the storage battery.



3. Remove the air supply sleeve (refer to 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 rail of the injector electrical connectors and the fuel rail (see Removing and installing fuel rail).



6. Turn out the screw of fastening of an arm of the indicator of level of oil.



7. Disconnect from an inlet pipe hoses of the vacuum amplifier of brakes and the valve of a purge of an adsorber.



8. Slide up the latch..




9.... and disconnect the wiring harness block from the throttle assembly cover.

Pic. 5.35. Intake pipe bolts.

10. Turn out seven bolts of fastening of an inlet pipe (pic. 5.35), and then remove it in assembly with the throttle assembly and the gasket installed under it.

11. Install intake pipe with new gasket. Tighten the fastening bolts evenly crosswise with a torque of 15 Nm (1.5 kgf·m), starting with the extreme 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 O-rings.

To replace the intake manifold gasket on 2.0L and 2.3L Duratec-HE engines, follow these steps.

You will need: TORX T25 wrench, 10 socket socket, flat blade screwdriver.


1. Reduce the pressure in the supply system (see Reducing the pressure in the engine supply system).

2. Disconnect a wire from the minus plug of the storage battery.



3. Remove the air supply sleeve (refer to Removing and installing the air filter and intake silencer).



4. Slide the latch..



5.... and disconnect the wiring harness block from the throttle assembly cover.


6. Disconnect the fuel line from the fuel rail (see Removing and installing fuel rail).



7. Disconnect the adsorber purge hose from the inlet pipe fitting.



8. Turn out the screw of fastening of an arm of the indicator of level of oil.



9. Turn out bolts of fastening of an inlet pipe..

NOTE: This is how the intake pipe mounting bolts are located.

10.... and remove the intake pipe assembly with the throttle assembly.



11. Remove old gaskets.

12. Install intake pipe with new gaskets. Tighten the fastening bolts evenly crosswise with a torque of 15 Nm (1.5 kgf·m), starting with the extreme 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 O-rings.