Peugeot 205 - Manual (Page 134)

2 In many cases it will be found easier to
remove the complete system from the car and
then to renew individual sections on the bench.
3 To remove the complete system, raise and
support the vehicle at a convenient working
height (see “Jacking and vehicle support”).
Apply penetrating oil to the nuts, bolts and
clamps which will have to be undone.
4 Where applicable, disconnect the oxygen
sensor wiring plug is disconnected before
removing the downpipe.
5 Unbolt the flanged joint at the union of the
exhaust system with the downpipe or at the
manifold connection. According to model,
unbolt the additional support brackets at the
transmission.
6 With the aid of an assistant, unhook the
system from its mountings and remove it.
7 With the system removed, undo the
retaining clamp bolts and separate the various
sections as required.
Refitting
8 Refitting is a reversal of removal, noting the
following points:
a) Ensure that all traces of corrosion have
been removed from the flanges and
renew all necessary gaskets.
b) Inspect the rubber mountings for signs of
damage or deterioration, and renew as
necessary.
c) When tightening a spring loaded flange
joint, tighten the flange mounting nuts
evenly so that the special springs are
compressed equally; approximately four
threads of the bolt should be visible and
the springs should be compressed to
approximately 22.0 mm.
d) Prior to tightening the exhaust system
fasteners, ensure that all rubber
mountings are correctly located, and that
there is adequate clearance between the
exhaust system and vehicle underbody.
3 Exhaust manifold - removal
and refitting 3
Removal
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).
Manoeuvre the manifold from the engine and
discard the manifold gaskets.
Refitting
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.
4D•4 Exhaust and emission control systems
3.5 Exhaust manifold upper retaining nuts
(arrowed)
2.1 Typical exhaust system layout