EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.0]

id0115z5953200

Replacement Part

Gasket
 
Quantity: 1
 
Location of use: Main silencer
Nut
 
Quantity: 4
 
Location of use: TWC
Exhaust manifold gasket
 
Quantity: 1
 
Location of use: Exhaust manifold (WU-TWC)
Gasket
 
Quantity: 1
 
Location of use: Exhaust manifold (WU-TWC)
Nut
 
Quantity: 5
 
Location of use: Exhaust manifold (WU-TWC)
—

Warning
•  A hot engine and exhaust system can cause severe burns. Turn off the engine and wait until they are cool before removing the exhaust system.

2WD

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove in the order indicated in the table.

3.  Remove the insulator. (See Exhaust System Insulator Removal/Installation (2WD).)

4.  Install in the reverse order of removal.

Step 1

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1
Main silencer
2
Tunnel cover
(See Tunnel cover Installation Note.)
3
Brace bar
(See Brace Bar Installation Note.)
4
Tunnel member
(See Tunnel Member Installation Note.)
5
Connector
6
TWC component
(See TWC component Removal Note (2WD).)
7
HO2S
(See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)
8
TWC

Step 2

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1
A/F sensor
2
Clip
3
Insulator
4
Exhaust manifold insulator
(See Exhaust Manifold Insulator Removal Note (2WD).)
(See Exhaust Manifold Insulator Installation Note (2WD).)
5
Exhaust manifold (WU-TWC)
(See Exhaust Manifold Removal Note (2WD).)
(See Exhaust Manifold Installation Note (2WD).)
6
Exhaust manifold gasket


Exhaust System Insulator Removal/Installation (2WD)

1.  Remove the floor under cover No.1 (RH). (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

2.  Remove the floor under cover No.2. (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

3.  Remove the tunnel cover. (See Tunnel cover Installation Note.)

4.  Remove the brace bar. (See Brace Bar Installation Note.)

5.  Remove the tunnel member. (See Tunnel Member Installation Note.)

6.  Remove the Mazda M Hybrid battery. (See Mazda M Hybrid BATTERY REMOVAL/INSTALLATION.)

7.  Remove in the order indicated in the table.

8.  Install in the reverse order of removal.

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1
Insulator (rear)
(See Insulator (rear) installation note.)
2
Insulator (front)
(See Insulator (front) installation note.)
3
Insulator (middle)
(See Insulator (middle) installation note.)


TWC component Removal Note (2WD)

1.  Remove the floor under cover No.1 (LH). (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

2.  Remove the TWC component.


Exhaust Manifold Insulator Removal Note (2WD)

1.  Remove the No.1 engine mount rubber bolt (transmission side), loosen the No.1 engine mount rubber bolt (cross member side), and move the engine slightly. (See ENGINE MOUNT DISASSEMBLY/ASSEMBLY [SKYACTIV-G 2.0].)

2.  Remove the insulator as shown in the figure.

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3.  Remove the exhaust manifold insulator.


Exhaust Manifold Removal Note (2WD)

Note
•  When removing the exhaust manifold, the bracket installed under the exhaust manifold does not have to be removed. Remove the exhaust manifold with the bracket installed.

1.  Remove the front crossmember. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

2.  Remove the exhaust manifold.


Exhaust Manifold Installation Note (2WD)

1.  Temporarily tighten the exhaust manifold installation nuts (1) and (2) shown in the figure by hand.

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2.  Tighten the exhaust manifold installation nuts (1) and (2) shown in the figure.

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3.  Temporarily tighten the exhaust manifold installation nuts (3) to (5) shown in the figure by hand.

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4.  Tighten the exhaust manifold installation nuts (3) to (5) shown in the figure.

5.  Tighten the exhaust manifold installation nuts (1) and (2) shown in the figure.

6.  Temporarily tighten the bolts (6) and (7) shown in the figure.

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7.  Tighten the bolt (6) shown in the figure.

8.  Tighten the bolt (7) shown in the figure.


Exhaust Manifold Insulator Installation Note (2WD)

1.  Temporarily tighten the exhaust manifold insulator.

2.  Tighten the exhaust manifold insulator in the order shown in the figure.

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AWD

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove in the order indicated in the table.

3.  Remove the insulator. (See Exhaust Manifold Insulator Removal Note (AWD).)

4.  Install in the reverse order of removal.

Step 1

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1
Main silencer
2
Tunnel cover
(See Tunnel cover Installation Note.)
3
Brace bar
(See Brace Bar Installation Note.)
4
Tunnel member
(See Tunnel Member Installation Note.)
5
Connector
6
TWC component
(See TWC component Removal Note (AWD).)
7
HO2S
(See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)
8
TWC

Step 2

a30zzw00005599

1
A/F sensor
(See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)
2
Clip
3
Insulator
4
Exhaust manifold insulator
(See Exhaust Manifold Insulator Removal Note (AWD).)
(See Exhaust Manifold Insulator Installation Note (AWD).)
5
Exhaust manifold (WU-TWC)
(See Exhaust Manifold Removal Note (AWD).)
(See Exhaust Manifold Installation Note (AWD).)
6
Exhaust manifold gasket


Exhaust System Insulator Removal/Installation

1.  Remove the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

2.  Remove the floor under cover No.1 (RH). (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

3.  Remove the floor under cover No.2. (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

4.  Remove the tunnel cover. (See Tunnel cover Installation Note.)

5.  Remove the brace bar. (See Brace Bar Installation Note.)

6.  Remove the tunnel member. (See Tunnel Member Installation Note.)

7.  Remove the Mazda M Hybrid battery. (See Mazda M Hybrid BATTERY REMOVAL/INSTALLATION.)

8.  Remove in the order indicated in the table.

9.  Install in the reverse order of removal.

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1
Insulator (rear)
(See Insulator (rear) installation note.)
2
Insulator (front)
(See Insulator (front) installation note.)
3
Insulator (middle)
(See Insulator (middle) installation note.)


TWC component Removal Note (AWD)

1.  Remove the floor under cover No.1 (LH). (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

2.  Remove the TWC component.


Exhaust Manifold Insulator Removal Note (AWD)

1.  Remove the No.1 engine mount rubber bolt (transmission side), loosen the No.1 engine mount rubber bolt (cross member side), and move the engine slightly. (See ENGINE MOUNT DISASSEMBLY/ASSEMBLY [SKYACTIV-G 2.0].)

2.  Remove the insulator as shown in the figure.

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3.  Remove the exhaust manifold insulator.


Exhaust Manifold Removal Note (AWD)

Note
•  When removing the exhaust manifold, the bracket installed under the exhaust manifold does not have to be removed. Remove the exhaust manifold with the bracket installed.

1.  Remove the front crossmember. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

2.  Remove the exhaust manifold.


Exhaust Manifold Installation Note (AWD)

1.  Temporarily tighten the exhaust manifold installation nuts (1) and (2) shown in the figure by hand.

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2.  Tighten the exhaust manifold installation nuts (1) and (2) shown in the figure.

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3.  Temporarily tighten the exhaust manifold installation nuts (3) to (5) shown in the figure by hand.

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4.  Tighten the exhaust manifold installation nuts (3) to (5) shown in the figure.

5.  Tighten the exhaust manifold installation nuts (1) and (2) shown in the figure.

6.  Temporarily tighten the bolts (6) and (7) shown in the figure.

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7.  Tighten the bolt (6) shown in the figure.

8.  Tighten the bolt (7) shown in the figure.


Exhaust Manifold Insulator Installation Note (AWD)

1.  Temporarily tighten the exhaust manifold insulator.

2.  Tighten the exhaust manifold insulator in the order shown in the figure.

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Insulator (middle) installation note

1.  Align the stud bolts shown in the figure with the insulator (middle) and install.

2WD

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AWD

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2.  Tighten the nuts to the specified torque.


Insulator (front) installation note

1.  Align the stud bolts shown in the figure with the insulator (front) and install.

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2.  Install the fasteners.

3.  Tighten the nuts to the specified torque.


Insulator (rear) installation note

1.  Align the stud bolt shown in the figure with the insulator (rear) and install.

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2.  Tighten the nuts to the specified torque.


Tunnel Member Installation Note

1.  Tighten bolt A shown in the figure to the specified torque.

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2.  Tighten bolt B shown in the figure to the specified torque.

3.  Tighten bolt C and nut C shown in the figure to the specified torque.

4.  Tighten bolt D shown in the figure to the specified torque.


Brace Bar Installation Note

1.  Tighten bolt A shown in the figure to the specified torque.

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2.  Tighten bolt B shown in the figure to the specified torque.

3.  Tighten the remaining bolts to the specified torque.


Tunnel cover Installation Note

1.  Install fastener A shown in the figure.

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2.  Install the remaining fasteners.

3.  Tighten the bolts shown in the figure to the specified torque.