Replacing the intake manifold gasket (Fusion)

There is a gasket installed between the cylinder head flanges and the intake manifold. If this gasket is not tight, the engine will run unevenly ("troit"). If the malfunction cannot be eliminated by tightening the intake manifold mount, replace the gasket.

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 fuel system").

2. Disconnect the wire from the negative terminal of the battery.



3. Remove the air supply hose (see "Removal and installation the air filter").



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 "Removal and installation 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.





10. Unscrew the seven bolts securing the intake pipe (Fig. 5.8) and remove the intake pipe assembly with the throttle assembly and the gasket installed underneath it.

11. Install the intake manifold with a new gasket. Tighten the mounting bolts evenly in a cross pattern, starting with the outer bolts and moving to the middle ones, to a torque of 15.0 N·m (1.5 kgf·m).

12. Install all removed parts in the reverse order of removal. When installing the fuel rail, use new fuel injector sealing rings.

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