Changing the manifold on one of these is possibly the easiest job I have ever done on a car. It could be argued it is easier than changing the passenger side headlight bulbs on one a Punto.
Don’t worry about it looking old and rusty they all do after a couple of days on the car due to the heat from the engine.
Tools needed the emergency jack, 13mm (at least I remember it as 13mm) socket and wrench plus smtall extension bar for wrench. Open ended spanner to fit the o2 sensors in the manifold. Your chosen release agent such as WD40 of plus gas (whatever works for you). Scraper to clean off old gasket. Torque wrench is good if you have access to one for checking the tightness of the manifold bolts once refitted but you can do it by feel.
Parts, replacement manifold/cat assembly, 2 x nuts for flang bolts on end of manifold, new exhaust gasket (about £3).
Instructions.
Couple of days before spray all bolts with release agent.
1. On the day, disconnect the multiplugs from the o2 sensors.
2. Lie on your back and reach under the car to undo the bolts holding the flange on the manifold to the centre section of the exhaust, these bolts may snap if they do do not panic as the bolts are part of the manifold and will be replaced.
3. Some cars have a support bracket from the exhaust to the clutch housing, mine had rusted away years ago, if present unbolt it.
4. If your heat shield is still present remove all the bolts (8 if i remember correctly) and lift off the heat shield.
5. Start to slacken the eight exhaust manifold securing nuts, 4 above and 4 below (use the extension bar to give you access to the lower bolts) Slacken all of them quarter turn at a time until they are loose or the last few may become really tight.
6. Once all the nuts are off slide the manifold towards you and off the studs and lower it to the ground. You can now jack up one side of the car to give clearance to slide the manifold out.
8. Use your spanner and a soft hammer (or other brute force item) to remove the o2 sensors from the manifold and then fit them to your new manifold.
7. Clean up the front of the engine to remove the old gasket and then slide the new gasket over the studs.
8. Refitting the exhaust is reverse of removal.
Never get under a car that is supported by only a jack, however in this case there should be no need to get under the car whilst it is raised. I also find that attacking old rusty bolts with a soft wire brush before attempting remove them clears the threads and stops them seizing as you undo them.