For 1990-2009 cars

## Exhaust Manifold Replacement 1.2L

### Removal Procedure

Warning: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

1. Remove the fuel pump fuse.
2. Start the engine. After it stalls, crank the engine after it stalls for 10 seconds to rid the fuel system of fuel pressure.
3. Disconnect the oxygen sensor connector.
4. Remove the catalytic converter. Refer to Catalytic Converter Replacement
5. Remove the exhaust manifold.

### Installation Procedure

Caution: Refer to Fastener Caution in the Preface section.

1. Install the exhaust manifold retaining bolts/nuts and tighten.

• | The exhaust manifold retaining bolts to 25 N·m (18.4 lb ft).

• | The exhaust manifold retaining nuts to 20 N·m (14.7 lb ft).

2. Install the catalytic converter. Refer to Catalytic Converter Replacement
3. Connect the heater outlet hose from the coolant pipe.
4. Install the exhaust manifold heat shield and tighten to 15 N·m (11 lb ft).
5. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.

## Exhaust Manifold Replacement 1.4L

### Removal Procedure

Warning: Refer to Battery Disconnect Warning in the Preface section.

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection
2. Disconnect the upper oxygen sensor connector.
3. Remove the exhaust manifold heat shield with engine oil indicator tube.
4. Remove the exhaust front pipe. Refer to Front Pipe Replacement.

Note: The exhaust manifold and the catalytic converter are one piece.

5. Remove the exhaust manifold with the gasket.

### Installation Procedure

Caution: Refer to Fastener Caution in the Preface section.

Note: Check the exhaust gasket surface whether cracks or damages or not.

1. Install the exhaust manifold with the gasket and tighten.

• | The exhaust manifold nuts to 20 N·m (14.7 lb ft).

• | The exhaust manifold lower bracket bolts to 20 N·m (14.7 lb ft).

2. Install the exhaust front pipe. Refer to Front Pipe Replacement.
3. Install the exhaust manifold heat shield with the engine oil indicator tube and tighten to 8 N·m (70.8 lb in).
4. Connect the upper oxygen sensor connector.
5. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.