EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop]

id0115c4800200

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 [MZR 2.0 DISI i-stop].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

3.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

4.  Remove in the order indicated in the table.

5.  Remove the exhaust system insulator. (See Exhaust System Insulator Removal/installation Note.)

6.  Install in the reverse order of removal.

am3zzw00012104

1
Main silencer
2
Tunnel member (rear)
3
TWC
4
HO2S
(See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)
5
A/F sensor
(See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)
6
insulator
7
Exhaust manifold insulator
(See Exhaust Manifold Insulator Removal Note.)
(SeeExhaust Manifold Insulator Installation Note.)
8
Exhaust manifold bracket
9
Exhaust manifold
(SeeExhaust Manifold Removal Note.)
(See Exhaust Manifold Installation Note.)
10
Exhaust manifold gasket


Exhaust System Insulator Removal/installation Note

1.  Remove the exhaust system insulator in the order shown in the figure.

2.  Install in the reverse order of removal.

am3zzw00012105

1
Insulator (rear No.1)
(See Insulator (rear No.1, No.2, No.3) removal note.)
2
Insulator (rear No.2)
(See Insulator (rear No.1, No.2, No.3) removal note.)
3
Insulator (rear No.3)
(See Insulator (rear No.1, No.2, No.3) removal note.)
4
Insulator (middle No.1)
5
Insulator (middle No.2)
6
Insulator (front)
(See Insulator (front) removal note.)


Insulator (rear No.1, No.2, No.3) removal note

Note
•  The insulator (rear No.1, No.2, No.3) are installed using rivets.

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

am3uuw00002778

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

ar8uuw00001479


Insulator (front) removal note

1.  Remove the tunnel member (front).

2.  Remove the insulator (front).


Exhaust Manifold Insulator Removal Note

1.  Set the engine harness out of way.

2.  Remove the exhaust manifold inslator.


Exhaust Manifold Removal Note

1.  Remove the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

2.  Remove the cowl grill. (See COWL GRILLE REMOVAL/INSTALLATION.)

3.  Remove the windshield wiper motor. (See WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.)

4.  Remove the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION.)

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

am3zzw00008537

6.  Remove the exhaust manifold.


Exhaust Manifold Installation Note

1.  Temporarily tighten the exhaust manifold installation nuts.

2.  Tighten the exhaust manifold new installation nuts in the order shown in the figure.

am3zzw00007797

Tightening torque
43—64 N·m {4.4—6.5 kgf·m, 32—47 ft·lbf}


Exhaust Manifold Insulator Installation Note

1.  Temporarily tighten the exhaust manifold insulator.

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

am3uuw00002495

Tightening torque
8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}