EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo]

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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 [MZR 2.3 DISI Turbo].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

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
Main silencer
2
Tunnel member
3
Middle pipe
(See Middle Pipe Installation Note.)
4
Seal ring (TWC side)
(See Seal Ring Removal Note.)
(See Seal Ring (TWC Side) Installation Note.)
5
TWC
(See TWC Installation Note.)
6
Seal ring (WU-TWC side)
(See Seal Ring Removal Note.)
(See Seal Ring (WU-TWC Side) Installation Note.)
7
HO2S
(See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo])
8
A/F sensor
(See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
9
Exhaust manifold upper insulator
(See Exhaust Manifold Upper Insulator Removal Note.)
10
WU-TWC insulator
(See WU-TWC Insulator Removal Note.)
11
Exhaust manifold lower insulator
12
WU-TWC bracket
13
Insulator
14
WU-TWC
(See WU-TWC Installation Note.)
15
Turbocharger
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
16
Exhaust manifold
(See Exhaust Manifold Installation Note.)
17
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.

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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)
(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).

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

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Insulator (Front) Removal Note

1.  Remove the tunnel member (front).

2.  Remove the insulator (front).


Seal Ring Removal Note

1.  Remove the seal ring using a flathead screwdriver being careful not to damage the pipe.

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Exhaust Manifold Upper Insulator Removal Note

1.  Remove the charge air cooler cover. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

2.  Remove the charge air cooler. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

3.  Remove the charge air cooler bracket. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

4.  Remove the exhaust manifold upper insulator.


WU-TWC Insulator Removal Note

1.  Remove the turbocharger insulator. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

2.  Remove the WU-TWC insulator.


Exhaust Manifold Installation Note

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

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


WU-TWC Installation Note

1.  Temporarily tighten No.1 shown in the figure.

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2.  Temporarily tighten No.2 shown in the figure.

3.  Temporarily tighten No.3 shown in the figure.

4.  Completely tighten No.1 shown in the figure.

Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

5.  Completely tighten No.2 shown in the figure.

Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

6.  Completely tighten No.3 shown in the figure.

Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}


Seal Ring (WU-TWC Side) Installation Note

Caution
•  If installation is performed without using the SST, the seal ring will be damaged and deformed, resulting in an incorrect installation. Always use the SST to install the seal ring.

1.  Temporarily install the seal ring to the pipe so that the seal ring is even with the flange.

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2.  Install the SST to the seal ring so that the SST is even with the flange.

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3.  Press in the seal ring by tapping the SST using a plastic hammer until the seal ring contacts the flange.

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TWC Installation Note

1.  Spray carbon remover (TB6601 or equivalent) on the flared section of the exhaust pipe.

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2.  Remove the carbon adhering to the flared section shown in the figure using a nylon brush or sandpaper (No. 400 or equivalent).


Seal Ring (TWC Side) Installation Note

Caution
•  If installation is performed without using the SST, the seal ring will be damaged and deformed, resulting in an incorrect installation. Always use the SST to install the seal ring.

1.  Temporarily install the seal ring to the pipe so that the seal ring is even with the flange.

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2.  Install the SST to the seal ring so that the SST is even with the flange.

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3.  Press in the seal ring by tapping the SST using a plastic hammer until the seal ring contacts the flange.

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Middle Pipe Installation Note

1.  Spray carbon remover (TB6601 or equivalent) on the flared section of the exhaust pipe.

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2.  Remove the carbon adhering to the flared section shown in the figure using a nylon brush or sandpaper (No. 400 or equivalent).