Table of contents: Removal 🠇 Refitting 🠇
Removal
1294 cc models
1. Remove the air cleaner housing as described in Section 2.
2. Slacken and remove the retaining screws and remove the shroud from the top of the exhaust manifold.
3. Chock the rear wheels then jack up the front of the vehicle and support it on axle stands (see "Jacking and vehicle support").
4. Slacken and remove the bolt securing the front pipe in position.
5. Undo the nuts securing the exhaust front pipe to the manifold, then free the front pipe and recover the gasket.
6. Undo the eight retaining nuts securing the manifold to the head.
7. Manoeuvre the manifold out of the engine compartment and discard the manifold gaskets.
1124 and 1360 cc models
8. Firmly apply the handbrake, then jack up the front of the vehicle and support it on axle stands (see "Jacking and vehicle support"). Where applicable, trace the lambda (oxygen) sensor wiring back to the connectors and disconnect them.
9. Slacken and remove the retaining screws and remove the shroud from the top of the exhaust manifold. It may be necessary to remove the engine lifting eye bracket from the left-hand end of the cylinder head, and undo the bolt and remove the oil dipstick tube. Feed the lambda sensor wiring through the hole in the top of the shroud as it is removed.
10. On some models, a second heat shield is fitted on the underside of the manifold, above the oil filter. Undo the bolts and remove the heat shield.
11. Undo the nuts securing the exhaust front pipe to the manifold, then remove the bolt securing the front pipe to its mounting bracket. Disconnect the front pipe from the manifold, and recover the gasket.
Caution: Do not place any strain on the flexible section of the exhaust front pipe (where fitted), it is easily damaged.
12. Undo the retaining nuts securing the manifold to the head. Manoeuvre the manifold out of the engine compartment, and discard the manifold gasket.
13. Note that on later models the manifold retaining nuts have been modified and what are termed "short nuts" are now fitted in place of the earlier "long nuts". To determine the type fitted, temporarily refit the manifold and gaskets over the studs and screw on a retaining nut. If the long nuts are fitted, there will be virtually no stud thread protruding past the end of the nut. With the short nuts there will be two or three turns of stud thread visible. If any nuts are damaged, all eight should be replaced with the later type short nuts. Note also that the torque setting for each type is different (see Specifications).
1587 cc (8-valve) models
14. Slacken and remove the retaining screws and remove the shroud from the top of the exhaust manifold.
15. Chock the rear wheels then jack up the front of the vehicle and support it on axle stands (see "Jacking and vehicle support").
16. Slacken and remove the bolt securing the front pipe in position.
17. Undo the nuts securing the exhaust front pipe to the manifold, then free the front pipe and recover the gasket.
18. Undo the eight retaining nuts securing the manifold to the head. Manoeuvre the manifold out of the engine compartment and discard the manifold gaskets.
1587 cc (16-valve) models
19. Remove the air cleaner housing as described in Section 2.
20. Slacken and remove the retaining screws and remove the shroud from the top of the exhaust manifold.
21. Pull out the dipstick then remove the upper section of the dipstick tube.
22. Chock the rear wheels then jack up the front of the vehicle and support it on axle stands (see "Jacking and vehicle support").
23. Remove the catalytic converter as described in Section 17.
24. Undo the four nuts securing the front pipe to the manifold.
25. Unscrew the nut securing the front pipe to the transmission mounting stud and recover the spring cup and spring. Move the front pipe so that the mounting stud engages with the elongated slot on the mounting bracket then withdraw the front pipe from under the car. Recover the pipe-to-manifold gasket.
26. Trace the wiring back from the lambda (oxygen) sensor to its wiring connector and disconnect the connector from the main wiring harness.
(Original can be viewed at: «peugeotbook.ru»)
27. Undo the ten retaining nuts securing the manifold to the cylinder head. Manoeuvre the manifold out of the engine compartment and discard the manifold gasket.
Refitting
28. Refitting is the reverse of the removal procedure, noting the following points:
- a) Examine all the exhaust manifold studs for signs of damage and corrosion. Remove all traces of corrosion and repair or renew any damaged studs. On 1360 cc models, refer to the information contained in paragraph 13 above concerning the different nut types.
- b) Ensure that the manifold and cylinder head sealing faces are clean and flat and fit the new manifold gaskets. On early 1360 cc and 1587 cc (8-valve) models, fibre gaskets are used, whereas on later units the gaskets are of stainless steel. Note that the two types must not be mixed on an engine.
- c) If the later type stainless steel gaskets are being used, ensure that the gasket is fitted with the raised sealing surface on the gasket face toward the manifold.
- d) Tighten the manifold retaining nuts to the specified torque. On 1587 cc (16-valve) models, tighten the nuts in the sequence shown (see illustration).
- e) Reconnect the front pipe to the manifold using the information given in Section 17.