A possible reason for the failure of the collector may be the use of leaded gasoline and non-recommended types of motor oils with a high content of sulfur and phosphorus.
Between the flanges of the cylinder head and the collector there is a sealing gasket made of pressed heat-resistant material reinforced with steel.
To remove the manifold on 1.6L Duratec Ti-VCT engines, follow these steps.
You will need: wrenches "for 13", "for 22", socket heads "for 10", "for 15", a screwdriver with a flat blade.
1. Remove the mudguard and crankcase protection (see Removal and installation of mudguard and crankcase protection).
2. Remove the front suspension subframe (see Removing and installing front suspension subframe).
NOTE: It is necessary to remove the subframe because it makes it difficult to access the collector mounting elements and does not allow the collector to be removed from the vehicle.
In the process of removing the subframe, two rubber suspension pads for the suspension of the exhaust system units are disconnected from the collector brackets.
3. Remove the right front wheel drive (see Removing and installing front wheel drives).
NOTE: It is necessary to remove the right front wheel drive because it makes it difficult to access the collector mounting elements.
4. Disconnect the wiring harness blocks of all four oxygen concentration sensors screwed into the collector..
NOTE: Two sensor pads are shown on the right side of the manifold. The sensor pads on the left side are located symmetrically with respect to the longitudinal axis of the vehicle.
5….and remove the sensor harnesses from the holders on the thermal screen of the collector.
6. Remove two bolts securing the protective shield to the collector..
7….and engine block…
8….and then remove the shield.
9. Turn out two bolts of fastening of an additional thermoscreen to a katkollektor in its back part..
NOTE: The second thermal screen fastening bolt is not visible in the photo, it is located symmetrically relative to the longitudinal axis of the car.
10….two bolts in front of it…
NOTE: The second thermal screen fastening bolt is not visible in the photo, it is located symmetrically relative to the longitudinal axis of the car.
11.... and remove the thermal screen by passing the wire harnesses of the oxygen concentration sensors into its holes.
12. Turn away two nuts of fastening of a flange of the additional muffler to a katkollektor.
USEFUL ADVICE: Before unscrewing the nuts securing the flange of the additional muffler to the collector, clean the protruding threaded ends of the studs from dirt and rust with a metal brush, and then treat them with an easily penetrating grease, such as WD-40.
13. Disconnect from the brackets of the main muffler of the pillow of its suspension (refer to Replacing the suspension cushions of the exhaust system), disconnect the flanges of the additional muffler and the collector..
14.... and then remove the gasket installed between the flanges.
USEFUL ADVICE: Replace the sealing gasket between the flanges of the collector and the additional muffler with a new one each time the connection is disassembled.
15. Turn out four bolts of fastening of an extension to the basis of a body and remove an extension.
16. Unscrew the two nuts securing the collector to the cylinder head on the right..
17.... and on the left, remove one bolt in the center (not visible in the photo) …
18….and then remove the collector…
19.... and a gasket installed on the studs of the block head.
USEFUL ADVICE: Replace the gasket of the collector with a new one each time the connection is disassembled.
20. If you are replacing a manifold and the new manifold does not have oxygen concentration sensors, unscrew the sensors from the removed manifold and install them on the new assembly.
NOTE: Please note that the oxygen sensor wiring harnesses are different lengths. In addition, the color of the pads and the insulation of the harnesses differ. Install the sensors in the same places on the new collector as they were on the old one.
21. Install the collector and all removed parts in the reverse order of removal. Tighten the nuts and bolt of the collector in the sequence shown in the photo, with the torque given in Appendix 1.
To remove the manifold on Duratec-HE 2.0L and 2.3L engines, follow these steps.
You will need: wrenches "for 13", "for 22", socket heads "for 10", "for 15", a screwdriver with a flat blade.
1. Remove the mudguard and crankcase protection (see Removal and installation of mudguard and crankcase protection).
2. Remove the front suspension subframe (see Removing and installing front suspension subframe).
NOTE: It is necessary to remove the subframe because it makes it difficult to access the collector mounting elements and does not allow the collector to be removed from the vehicle.
In the process of removing the subframe, two rubber suspension pads for the suspension of the exhaust system units are disconnected from the collector brackets.
3. Remove the right front wheel drive (see Removing and installing front wheel drives).
NOTE: It is necessary to remove the right front wheel drive because it makes it difficult to access the collector mounting elements.
4. Disconnect the wiring harness blocks of the two oxygen concentration sensors screwed into the collector.
5. Remove two bolts securing the protective shield to the collector..
6.... and to the engine block..
7.... then remove the shield.
8. Unscrew the two nuts securing the flange of the additional muffler to the collector..
USEFUL ADVICE: Before unscrewing the nuts securing the flange of the additional muffler to the collector, clean the protruding threaded ends of the studs from dirt and rust with a metal brush and treat them with an easily penetrating grease, such as WD-40.
9.... and disconnect the flanges of the additional silencer and the collector.
10. Remove the gasket installed between the flanges.
USEFUL ADVICE: Replace the sealing gasket between the flanges of the collector and the additional muffler with a new one each time the connection is disassembled.
11. Turn out four bolts of fastening of an extension to the basis of a body and remove an extension.
12. Turn out bolts of fastening of a protective screen of a katkollektor…
13….and remove the protective screen.
14. Turn away nuts of fastening of a katkollektor to a head of the block of cylinders, remove katkollektor and the lining established on hairpins of a head of the block.
USEFUL ADVICE: Replace the gasket of the collector with a new one each time the connection is disassembled.
15. Install the collector and all removed parts in the reverse order of removal. Tighten the collector mounting nuts evenly crosswise, starting with the middle bolts and moving to the extreme torque given in Appendix 1.
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