Attention: before starting this work, the engine must be completely cooled down.
1. Disconnect the negative cable from the battery.
2. Disconnect the oxygen sensor cable (λ-sensor) and its fixtures. If manifold replacement is required, remove the oxygen sensor as well (see chapter 6).
3. Turn away three bolts of fastening of a protective casing of a collector, remove a casing, a pipe of recirculation of the fulfilled gases (further ROG) and air intake tube (if installed).
4. Lubricate the manifold bolts and nuts with oil, fuel or brake fluid.
5. Raise the vehicle and place it securely on stands.
6. Working from underneath the vehicle, lubricate the two bracket-to-manifold mounting bolts and the three muffler pipe self-locking nuts with oil or brake fluid.
Pic. 6.3a Assembling a typical exhaust manifold (carbureted engines)
Pic. 6.3b Assembling a typical exhaust manifold (petrol injection engines)
7. Turn away nuts of fastening of a pipe of the muffler and disconnect it from a collector.
8. Turn away nuts and disconnect a collector and linings
9. Lower the car.
10. Turn away nuts and disconnect a collector and linings.
11. Clean the mating surfaces of the manifold and cylinder head from gasket residues and coke deposits. If there are traces of exhaust gas leaks along the gasket, check the manifold for warping of the mating plane and, if necessary, restore the flatness.
12. Install new cylinder head gaskets.
13. Install the exhaust manifold.
14. Tighten nuts of fastening of a collector from the center to periphery with the effort specified in the specification to this Chapter.
15. Install the removed units in the reverse order of removal. We recommend using new self-locking nuts and gaskets. The tightening torques of threaded connections are specified in the specification.
16. Start the engine and check for exhaust gas leaks.