EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5]

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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 2.0, MZR 2.5].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)

3.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)

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.

MZR 2.0

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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 2.0, MZR 2.5].)
4
A/F sensor
(See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)
5
Exhaust manifold insulator
(See Exhaust Manifold Installation Note.)
6
insulator
7
Exhaust manifold bracket
8
Exhaust manifold
(See Exhaust Manifold Removal Note.)
(See Exhaust Manifold Installation Note.)
9
Exhaust manifold gasket

MZR 2.5

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1
Main silencer
2
Tunnel member (rear)
3
TWC
4
HO2S
(See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)
5
A/F sensor
(See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)
6
insulator
7
Exhaust manifold insulator
(See Exhaust Manifold Installation Note.)
8
Exhaust manifold bracket
9
Exhaust manifold
(See Exhaust 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.

MZR 2.0

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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 (middle No.1)
4
Insulator (middle No.2)
5
Insulator (front)

MZR 2.5

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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)


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).

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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 (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 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.

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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.

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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.

MZR 2.0

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MZR 2.5

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