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Section 75 (1.6L SOHC Engine): Manifold-Exhaust: Installation

WARNING: This page is about a different car, the 2006 Chrysler PT Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Exhaust Manifold, Heat Shield, and Gasket
GC0021558Courtesy of DAIMLERCHRYSLER CORP.
  1. Clean gasket surfaces.
  2. Install exhaust manifold with a new gasket and install bolts to hold gasket in place. See Fig 1. The gasket has tabs in the bolt holes to retain the exhaust manifold bolts for installation purposes.
  3. Tighten the exhaust manifold bolts in a spiral pattern starting with the center bolts and working outward. Tighten bolts to 23 N.m (200 in. lbs.).
  4. Install exhaust manifold upper heat shield and tighten bolts to 28 N.m (250 in. lbs.).
    Fig 2: Heat Shield Bolt
    GC0042444Courtesy of DAIMLERCHRYSLER CORP.
  5. Raise vehicle on hoist.
  6. Install the starter heat shield bolt. See Fig 2.
    Fig 3: Exhaust Manifold, Heat Shield, and Gasket
    GC0021558Courtesy of DAIMLERCHRYSLER CORP.
  7. Install the exhaust pipe to the exhaust manifold. Tighten bolts to 28 N.m (250 in. lbs.).
  8. Lower vehicle.
  9. Install ignition coil and spark plug cables (Refer to ELECTRICAL/IGNITION CONTROL/IGNITION COIL - INSTALLATION) .
  10. Connect ignition coil and capacitor electrical connector.
  11. Connect negative battery cable.
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