EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.0]

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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 [SKYACTIV-G 2.0].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)

3.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)

4.  Remove in the order indicated in the table.

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

6.  Install in the reverse order of removal.

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1	Main silencer
2	Brace bar
3	TWC
4	HO2S (See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)
5	A/F sensor (See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)
6	insulator (See Insulator Removal Note.)
7	Clip
8	Exhaust manifold insulator (upper) (See Exhaust Manifold Insulator (Upper) Removal Note.) (See Exhaust Manifold Insulator (Upper) Installation Note.)
9	Exhaust manifold bracket installation bolt (See Exhaust Manifold Bracket Installation Bolt Removal Note.) (See Exhaust Manifold Bracket Installation Bolt Installation Note.)
10	Exhaust manifold (WU-TWC) (See Exhaust Manifold Removal Note.) (See Exhaust Manifold Installation Note.)
11	Exhaust manifold insulator (lower)
12	Exhaust manifold gasket
13	Exhaust manifold bracket

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 Exhaust Manifold Insulator (Upper) 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 Removal Note

Note

•  If the exhaust manifold insulator (upper) is to be removed, remove the insulator. However, if the exhaust manifold is to be removed, the insulator does not have to be removed.

Exhaust Manifold Insulator (Upper) Removal Note

Note

•  If the exhaust manifold insulator (upper) is to be removed, use the following procedure: However, if the exhaust manifold is to be removed, the following procedure does not have to be performed: Refer to the exhaust manifold installation note.

1.  Remove the bolt as shown in the figure.

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2.  Set the coolant reserve tank aside with the hose connected.

3.  Remove the wiring harness bracket shown in the figure.

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4.  Remove the bolt shown in the figure and set the bracket aside.

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5.  Remove the aerodynamic under cover No.2. (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.)

6.  Remove the No.1 engine mount rubber installation bolt. (See ENGINE REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)

Caution

•  To prevent deformation of the oil pan, support the engine using the following methods.

―  When using an engine lifter, insert rubber of appropriate size (approx. 20 mm {0.79 in} thickness) between the engine lifter and the oil pan to support the oil pan.

―  When using a garage jack, place rubber of appropriate size (approx. 20 mm {0.79 in} thickness) on a batten which is large enough to cover the oil pan to support the oil pan.

7.  Before removing the No.3 engine mount installation bolts, support the engine (oil pan) using a commercially available engine lifter or garage jack.

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8.  Remove the No.3 engine mount installation bolt (frame side). (See ENGINE REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)

9.  Cover the frame with tape.

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10.  Move the engine towards the vehicle front referring to the movement of the No.3 engine mount.

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11.  Remove the exhaust manifold insulator (upper) as shown in the figure.

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Exhaust Manifold Bracket Installation Bolt Removal Note

1.  Remove the aerodynamic under cover No.2. (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.)

2.  Remove the exhaust manifold bracket installation bolt.

Exhaust Manifold Removal Note

Note

•  For the exhaust manifold insulator (upper) removal procedure when removing the exhaust manifold, refer to the following procedure:

1.  Remove the exhaust manifold insulator (upper) installation bolt.

2.  Remove the front crossmember. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop, SKYACTIV-G 2.0].)

3.  Remove the exhaust manifold insulator (upper).

4.  Remove the exhaust manifold.

Exhaust Manifold Installation Note

1.  Temporarily tighten the exhaust manifold installation nuts (1) and (2) shown in the figure by hand.

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2.  Tighten the exhaust manifold installation nuts (1) and (2) shown in the figure to 33—53 N·m.

3.  Temporarily tighten the exhaust manifold installation nuts (3) to (5) shown in the figure by hand.

4.  Tighten the exhaust manifold installation nuts (3) to (5) shown in the figure.

5.  Tighten the exhaust manifold installation nuts (1) and (2) shown in the figure.

Exhaust Manifold Bracket Installation Bolt Installation Note

1.  Tighten the exhaust manifold bracket installation bolt in the order shown in the figure.

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Exhaust Manifold Insulator (Upper) Installation Note

1.  Temporarily tighten the exhaust manifold insulator (upper).

2.  Tighten the exhaust manifold insulator in the order shown in the figure (upper).

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