TAILPIPE REPLACEMENT [MZR 1.5, MZR 1.6]

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Caution

•  Be careful not to deform the pipe when cutting it. If the pipe is deformed, it may not be possible to install the new tailpipe correctly.

•  If the pipe is tightened to the U-bolt, the pipe will deform. Consequently, the pipe may not install correctly when reassembling it. Therefore, if the pipe has already been connected by the U-bolt, replace the main silencer as a single unit.

1.  Measure the indicated length from the center bottom surface of the hanger rod (round bar) to the cut surface.

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2.  Mark the position (1) shown in the figure (joint pipe installation position).

3.  Cut the pipe between the main silencer and the tailpipe in the position shown in the figure.

4.  Remove burrs from the cut surface on the main silencer side using a file.

5.  Mark the joint pipe in the position (2) shown in the figure (U-shaped bolt installation position).

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6.  Mark the new tailpipe in the position (3) shown in the figure (joint pipe installation position).

7.  Install the new tailpipe to the main silencer using the following procedure.

(1)  Apply silicone sealant to the specified positions of the main silencer and tailpipe along the entire perimeter.

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(2)  Insert the U-shaped bolt into the joint pipe.

(3)  Engage the joint pipe with the main silencer.

(4)  Engage the new tailpipe with the joint pipe.

(5)  Secure the exhaust pipe to the rubber hanger.

(6)  Align the cut surface on the joint pipe with the marked positions (1) and (3).

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(7)  Verify that the exhaust pipe is installed without any twisting of the pipe.

8.  Tighten the U-shaped bolt between the main silencer and the new tailpipe using the following procedure.

(1)  Align the thin part of the U-shaped bolt with the marked position (2).

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(2)  Set the U-shaped bolt so that the clearance between the bolt and surrounding parts is as shown in the figure.

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A: Clearance between the U-shaped bolt and the rear crossmember

25 mm {0.98 in} or more

Caution

•  Do not loosen the U-shaped bolt after tightening it. If it is loosened, the bolt cannot be retightened to the specified torque with the specified projection.

•  Tighten the U-shaped bolt in three or four steps, on the left and right sides equally, to prevent clamp deformation.

(3)  Tighten the U-shaped bolt while verifying that the marking for the tailpipe end points to the bottom of the vehicle.

Projection of U-shaped bolt after tightening

9—11 mm {0.36—0.43 in}