Exhaust manifold - removal and refitting

2.0 litre SOHC models 1 Refer to Chapter 4 Part A, Section 26, but note the following points.

2 Ignore the references to removal and refitting of the air cleaner and hot air pick-up pipe, and note that a heat shield is fitted in place of the hot air shroud.

3 Note the location of the inlet manifold bracing strut which is secured to one of the manifold studs by an extra nut.

2.0 litre DOHC models
Note: A new manifold gasket must be used on refitting.

4 Disconnect the battery negative lead.

5 Disconnect the wiring plug from the idle speed control valve at the front of the plenum chamber.

6 Loosen the clamp, and detach the air inlet hose from the air inlet tubing.

7 Unscrew the securing nut, and release the air inlet tube from the bracket on the engine compartment front panel.

8 Release the air cleaner lid securing clips, then lift away the air inlet tube, plenum chamber and air cleaner lid as an assembly disconnecting the breather hose from the air inlet tube.

9 On models with a catalytic converter, disconnect the exhaust gas oxygen sensor wiring plug.

10 Unscrew the securing nuts, and disconnect the exhaust downpipe from the manifold. Recover the gasket. Support the exhaust downpipe from underneath the vehicle (eg with an axle stand) to avoid placing unnecessary strain on the exhaust system.

11 Unscrew the six securing nuts, and lift the manifold from the cylinder head. Recover the gasket.

12 Refitting is a reversal of removal, bearing in mind the following points.

13 Ensure that all mating faces are clean, and use a new gasket.

14 Tighten the manifold securing nuts and the downpipe securing nuts progressively to the specified torque (where given).

1.6 and 1.8 litre (R6A type) CVH models
Note. A new manifold gasket and downpipe gaskets must be used on refitting.

15 Disconnect the battery negative lead.

16 Remove the air cleaner and, where fitted, pull the hot-air pick-up pipe from the exhaust manifold hot-air shroud.

17 On 1.6 litre engines, remove the pulse-air delivery tubing.

18 Remove the securing bolts, and withdraw the hot-air shroud from the manifold.

19 Disconnect the exhaust gas oxygen sensor wiring plug. Unscrew the securing nuts, and disconnect the exhaust downpipe from the manifold. Recover the gasket.

Support the exhaust downpipe from underneath the vehicle (eg with an axle stand) to avoid placing unnecessary strain on the exhaust system.

20 Unscrew the securing nuts, and lift the manifold from the cylinder head. Recover the gasket.

21 Refitting is a reversal of removal, bearing in mind the following points.

22 Ensure that all mating faces are clean, and renew all gaskets.

23 Tighten the manifold securing nuts progressively to the specified torque, and similarly tighten the exhaust downpipe securing nuts.

Exhaust system - inspection, removal and refitting

1 Refer to Chapter 4 Part A, Section 27.

2 On all models except 2.0 litre SOHC, flanged joints incorporating gaskets may be used to join exhaust sections on certain models. Where applicable, renew the gaskets on refitting.

3 On models fitted with a catalytic converter, disconnect the battery negative lead and disconnect the exhaust gas oxygen (HEGO) sensor wiring plug before removing the downpipe.

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