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Replacing the Exhaust Manifold Gasket

Model: Ford Focus MK 1 - Years 1998-2004
Part: Engine

Before installing the new gasket, it is essential to thoroughly clean the mating surfaces, both on the manifold side and the cylinder head side. Remove any dirt or deposits that could compromise the gasket's adherence and seal, causing leaks that may generate annoying noise.
Once cleaning is complete, align the new gasket without applying sealant and install the manifold, tightening the respective nuts in a cross pattern using a torque wrench.

Updated on 15 February 2026 by ScegliAuto

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Lift the vehicle on suitable axle stands, remove the front wheels, and then the front bumper and grille. Proceed to remove the front headlights; drain the coolant, remove the intercooler radiator and the hoses connecting it to the intake system. Position the new intercooler radiator in the grille, temporarily securing it with cable ties, and mark with a marker the part of the metal that needs to be removed to allow the new hoses to pass through. Cut the marked portion of metal and apply a gasket to the edge. Remove the inner cover of the bumper and position it near the radiator to identify any interfering parts to eliminate: again, apply a gasket to the edge of the cut. Create brackets for securing the new radiator and proceed with the installation of the connecting pipes from the radiator to the intake, shaping and connecting them appropriately. Finally, reassemble the bumper, headlights, and grille.

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