Contents: Removal ⇓ Installation ⇓
Exhaust manifold mounting elements for 1.6 and 1.8 liter engines
1 - heat-protective casing;
2 - graduate collector
3 - gasket;
4 - cylinder head.
Warning: Gasoline is extremely flammable, so use extreme caution and care when working with any part of the fuel system. Do not smoke or allow open flames in the work area. If gasoline comes into contact with your skin, wash it off immediately with plenty of water and soap. When working on any part of the fuel system, wear safety glasses and have a fire extinguisher on hand.
Exhaust manifold mounting elements for 2.0 liter engines
1 - exhaust manifold
2 - oxygen sensor
3 - heat-protective casing
Intake manifold mounting elements for 2.0 liter engines
1 - intake manifold
2 - coil
3 - throttle body
4 - intake manifold spacer
Removal
Disconnect the negative battery cable.
Drain the cooling system.
Remove the air cleaner.
Tag and disconnect all vacuum hoses, electrical wiring, and fuel lines.
Disconnect the accelerator rod from the throttle linkage.
Remove the valve body from the intake manifold.
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Disconnect the fuel supply hose from the fuel filter.
Disconnect the coolant hose bracket.
Disconnect the heat shield and warm air intake.
Remove the intake manifold nuts and remove the manifold from the engine.
Loosen the nuts and remove the exhaust manifold.
Installation
Clean the cylinder head studs with solvent and dry them with compressed air.
Check the contact surfaces of the collectors for evenness using a precision measuring instrument.
Check the manifolds for cracks, damage or destruction.
If the manifold is cracked or damaged, replace it or see if the existing one can be repaired at a specialist workshop.
Using a special tool, remove all traces of old gasket material from the contact surfaces of the cylinder head and manifolds. Clean surfaces with solvent or acetone.
Install the exhaust manifold with new gaskets and tighten the center nut finger tight. Then install the intake manifold. Starting from the center and working toward the edges, tighten the nuts in a crisscross pattern
Reinstall the remaining components by following the steps described for removal in reverse order.