EXHAUST SYSTEM REMOVAL/INSTALLATION[ZJ, ZY, Z6]

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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.

1.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION[ZJ, ZY, Z6].)

2.  Disconnect the negative battery cable.

3.  Before disconnect the engine coolant hose, drain the engine coolant. (See ENGINE COOLANT REPLACEMENT[ZJ, ZY, Z6].) (with throttle valve actuator)

4.  Remove the under cover.

5.  Remove in the order indicated in the table.

6.  Install in the reverse order of removal.

7.  Inspect the front wheel alignment and adjust it if necessary. (See FRONT WHEEL ALIGNMENT.)

Without throttle valve actuator

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1
Rear tunnel member
2
Front tunnel member
3
Main silencer
4
Rear HO2S
(See REAR HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION[ZJ, ZY, Z6].)
5
Front HO2S
(See FRONT HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION[ZJ, ZY, Z6].)
6
Member
7
Exhaust manifold bracket
8
Exhaust manifold
(See Exhaust Manifold/Exhaust Manifold Insulator Removal Note.)
(See Exhaust Manifold Installation Note.)
9
Exhaust manifold insulator
(See Exhaust Manifold/Exhaust Manifold Insulator Removal Note.)
10
Exhaust manifold gasket

With throttle valve actuator

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1
Rear tunnel member
2
Front tunnel member
3
Main silencer
4
Rear HO2S
(See REAR HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION[ZJ, ZY, Z6].)
5
Front HO2S
(See FRONT HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION[ZJ, ZY, Z6].)
6
EGR cooler
(See EGR COOLER REMOVAL/INSTALLATION[ZJ, ZY, Z6].)
7
Member
8
Exhaust manifold bracket
9
Exhaust manifold
(See Exhaust Manifold/Exhaust Manifold Insulator Removal Note.)
(See Exhaust Manifold Installation Note.)
10
Exhaust manifold insulator
(See Exhaust Manifold/Exhaust Manifold Insulator Removal Note.)
11
Exhaust manifold gasket


Exhaust Manifold/Exhaust Manifold Insulator Removal Note

Caution
•  Over bending of the exhaust flexible pipe may cause damage resulting in failure.
Note
•  When removing the exhaust manifold, move the exhaust manifold insulator slightly out of the way, loosen the nuts, then remove the exhaust manifold together with the insulator. Refer to the following procedure.

1.  Remove the front wheels and tires.

2.  Perform the following procedure for easier access.

Except U.K. specs.
1.  Remove the air cleaner cover and the air cleaner case. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION[ZJ, ZY, Z6].)
U.K. specs.
1.  Set the air cleaner cover out of the way. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION[ZJ, ZY, Z6].)
2.  Remove the air cleaner case.

3.  Disconnect the steering shaft from the steering gear and linkage side. (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION.)

4.  Disconnect the pressure hose and the return hose. (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION.)

5.  Remove the No.1 engine mount rubber. (See ENGINE REMOVAL/INSTALLATION[ZJ, ZY, Z6].)

6.  Loosen the exhaust manifold insulator bolts.

7.  Move the exhaust manifold insulator slightly out of the way and loosen the exhaust manifold nuts.

8.  Remove the installation bolts of the front stabilizer and front crossmember component. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

9.  Loosen the front crossmember component installation bolts and lower the front crossmember component approx. 100 mm {3.94 in}. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

10.  Support the flexible pipe with a support wrap or splint as shown in the figure.

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11.  Remove the exhaust manifold together with the insulator by lowering it to the underside of the vehicle.


Exhaust Manifold Installation Note

1.  Tighten the exhaust manifold installation nuts in the order shown in the figure.

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