DIY: Remove and replace the inlet manifold on a Ford Duratec HE or Mazda LF engine in a Mondeo Mk3, Focus Mk2, or some Mazdas and Volvos. Early Duratecs in the Mondeo particularly had swirl flaps that wore too easily and could destroy the engine. You also need to remove the manifold to access the PCV valve & hose, plus the knock sensor.
It's also good practice to drain the oil that accumulates inside and give the interior a bit of a clean.
Video on the swirl flaps: https://youtu.be/amRXA22ofds
Video on the PCV valve and hose: https://youtu.be/-TR4pZdXZpg
If you need to replace the manifold gaskets, the part # (individual, you need four) is F1119284....
Amazon US: http://amzn.to/2bV8sLi | UK: http://amzn.to/2cpztel
... and the EGR inlet seal # is F1119833.
You will need:
- Jack and axle stands, or other way to get under car front
- Screwdriver blade or similar to release air intake clip, and long nose pliers to redo
- Socket set or spanners
- 10 mm socket with 1/4" or 3/8" wrench and (important) variable length extension bar(s) as shown
- Blu-Tack or other way of grabbing bolts (e.g. magnetic socket head)
- Masking tape
- Small mirror
- Flashlight
- Ideally: Torque wrench for 18 nm manifold bolts
- Brake clean
- Rag(s).
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