EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6]

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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.
Note
•  If the tailpipe cut and main silencer removal work are performed at the same time, the rear crossmember removal is unnecessary.

1.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

3.  Remove in the order indicated in the table.

4.  Remove the exhaust system insulator. (See Exhaust System Insulator Removal/Installation Note.)

5.  Install in the reverse order of removal.

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1
Tunnel member
2
Main silencer
(See Main Silencer Removal Note (Only If Tailpipe Is Not Cut Off).)
3
HO2S
(See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)
4
A/F sensor
(See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)
5
Exhaust manifold insulator
(See Exhaust Manifold Insulator Removal Note.)
6
Exhaust manifold bracket
7
Exhaust manifold
(See Exhaust Manifold Removal Note.)
(See Exhaust Manifold Installation Note.)
8
Exhaust manifold gasket


Exhaust System Insulator Removal/Installation Note

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1
Insulator (rear No.1)
(See Insulator (rear No.1, No.2) removal note.)
2
Insulator (rear No.2)
(See Insulator (rear No.1, No.2) removal note.)
3
Insulator (middle No.1)
4
Insulator (middle No.2)
5
Insulator (front)


Insulator (rear No.1, No.2) removal note

Note
•  The insulator rear is installed using rivets.
•  When reinstalling the rivet, install the same rivet or M5 bolt and nut.

1.  Push out the mandrel using a hammer and punch (2—2.8 mm {0.08—0.11 in} diameter).

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2.  Remove the flange using a drill (5 mm {0.20 in} drill bit).

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Main Silencer Removal Note (Only If Tailpipe Is Not Cut Off)

1.  Remove the following parts:

(1)  Rear auto leveling sensor (Vehicles with AFS) (See AUTO LEVELING SENSOR REMOVAL/INSTALLATION.)
(2)  Rear stabilizer (See REAR STABILIZER REMOVAL/INSTALLATION.)
(3)  Rear coil spring (See REAR COIL SPRING REMOVAL/INSTALLATION.)
(4)  Rear lower arm (See REAR LOWER ARM REMOVAL/INSTALLATION.)
(5)  Rear crossmember (See REAR CROSSMEMBER REMOVAL/INSTALLATION.)

2.  Remove the main silencer.


Exhaust Manifold Insulator Removal Note

1.  Remove the air cleaner cover. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

2.  Remove the EGR pipe (exhaust manifold side). (Vehicles with EGR system) (See EGR PIPE REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

3.  Remove the exhaust manifold insulator.


Exhaust Manifold Removal Note

1.  Remove the following parts:

(1)  Joint cover (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITHOUT ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM].) (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITH ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM].)
(2)  Disconnect the steering shaft from the steering gear and linkage. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITHOUT ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM].) (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITH ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM].)
(3)  Front auto leveling sensor (Vehicles with AFS) (See AUTO LEVELING SENSOR REMOVAL/INSTALLATION.)
(4)  Front ABS wheel-speed sensor wiring harness connector (See FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION.)
(5)  Front crossmember component (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6, MZR 2.0, MZR 2.3 DISI Turbo, MZR 2.5, MZ-CD 1.6].)

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

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3.  Remove the exhaust manifold.


Exhaust Manifold Installation Note

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

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