Peugeot 205 Manual

Exhaust manifold - removal and refitting
Exhaust and emission control systems / Exhaust manifold - removal and refitting

1 Disconnect the battery negative lead.

2 Where applicable, disconnect the hot-air inlet hose from the manifold shroud and remove it from the vehicle. Slacken and remove the three retaining screws, and remove the shroud from the top of the exhaust manifold
3 Firmly apply the handbrake, then jack up the front of the vehicle and support it on axle stands (see Jacking and vehicle support).

4 Undo the nuts/bolts securing the front downpipe to the manifold then, according to model, remove the bolt securing the pipe to its mounting bracket. Disconnect the downpipe from the manifold.

5 Undo the retaining nuts securing the manifold to the cylinder head (see illustration).

3.5 Exhaust manifold upper retaining nuts (arrowed)
3.5 Exhaust manifold upper retaining nuts (arrowed)

Manoeuvre the manifold from the engine and discard the manifold gaskets.

6 Refitting is the reverse of the removal procedure, noting the following points: a) Examine all the exhaust manifold studs for signs of damage and corrosion; remove all traces of corrosion, and repair or renew any damaged studs.

b) Ensure that the manifold and cylinder head sealing faces are clean and flat, and fit the new manifold gaskets.

c) Reconnect the downpipe to the manifold using the information given in Section 2.

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