Exhaust manifold - removal and refitting

Removal

2.0 litre 16-valve models

1. Raise and securely support the front of the vehicle.

2. Disconnect the battery earth (negative) lead.

3. Remove the manifold heat shield, which is secured by three bolts at the top and two of the manifold nuts at the bottom (see illustration).

Removing an exhaust manifold heat shield bolt

4. Remove the remaining 10 nuts which secure the manifold.

5. On models with an oxygen sensor, disconnect the sensor multiplug (near the right-hand suspension mounting) and free the wiring leading to the sensor.

5. Working under the vehicle, unbolt the manifold-to-exhaust system flexible joint and support bracket (see illustration).

Manifold-to-exhaust system joint and bracket

6. Lift away the manifold and recover the gasket.

All other models

7. On models with an oxygen sensor, disconnect the sensor multiplug and free the wiring to prevent it being strained whilst the manifold is removed.

Refitting

8. Refitting is the reverse of the removal procedure, using a new manifold gasket (see illustration).

Fitting a new exhaust manifold gasket

Exhaust system - inspection, removal and refitting

On models with an oxygen sensor, it will be necessary to disconnect the sensor multi-plug and free the wiring from its retaining clips before removal.

On refitting ensure the sensor wiring is correctly routed and in no danger of contacting the exhaust system.