Table of contents: Removal 🠇 Installation 🠇
Removal
1. On models with a 1.4L engine with secondary air injection, remove the secondary air injection valve as described in chapter 4G.
2. Fully apply the parking brake. Raise the front of the vehicle and support it securely (see "Lifting and installing the car on supports").
3. Trace the oxygen sensor wiring back to the electrical connectors and disconnect them.
4. Remove the bolts and the cover from the top of the exhaust manifold (figure 15.4). It may be necessary to remove the engine lift bracket from the left end of the cylinder head, remove the bolt and remove the oil dipstick tube. Feed the oxygen sensor wiring through the hole in the top of the housing when removing the housing.
Figure 15.4. Remove the bolts (marked with arrows) and remove the cover from the top of the exhaust manifold
5. On some models, a second heat shield is installed on the underside of the manifold, above the oil filter. Remove the bolts and heat shield.
6. Remove the exhaust pipe/catalytic converter mounting nuts from the manifold, then remove the exhaust pipe mounting bolt from the corresponding support bracket. Disconnect the exhaust pipe from the manifold and remove the gasket.
7. Unscrew the nuts securing the manifold to the cylinder head. Remove the manifold from the engine compartment and discard the manifold gasket.
Installation
8. Installation is carried out in the reverse order of removal, taking into account the following points:
- a) Inspect all exhaust manifold studs for signs of damage and corrosion; remove all traces of corrosion and repair or replace damaged studs.
- b) Clean and dry the mating surfaces of the manifold and cylinder head and ensure that they are not deformed. Install new manifold gasket(s). Tighten the manifold mounting nuts to the specified torque.
- c) Connect the intake pipe to the manifold using the information given in paragraph 16.
- d) If necessary, replace the oil dipstick tube sealing ring.