EXHAUST SYSTEM REMOVAL/INSTALLATION [ZY, Z6]

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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 [ZY, Z6].)

2. Disconnect the negative battery cable.

3. Remove the under cover.

4. Remove in the order indicated in the table.

5. Install in the reverse order of removal.

.

1
Rear tunnel member
2
Front tunnel member
3
Main silencer
4
Rear heated oxygen sensor
5
Front heated oxygen sensor
6
EGR pipe (Exhaust manifold side)
7
Member
8
Exhaust manifold bracket
9
Clip
10
WU-TWC
11
Exhaust manifold insulator
12
Exhaust manifold gasket

Exhaust Manifold/Exhaust Manifold Insulator Removal Note

Caution
• Over bending of the exhaust flexible pipe may cause damage resulting in failure.
Note
• When removing the exhaust manifold, move the exhaust manifold insulator slightly out of the way, loosen the nuts, then remove the exhaust manifold together with the insulator. Refer to the following procedure.

1. Remove the front wheels and tires.

2. Remove the air cleaner cover and the air cleaner case. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [ZY, Z6].)

3. Remove the EGR pipe (Intake manifold side). (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [ZY, Z6].)

4. Remove the EGR valve component. (See EGR VALVE REMOVAL/INSTALLATION [ZY, Z6].)

5. Disconnect the steering shaft from the steering gear and linkage side. (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION.)

6. Disconnect the pressure hose and the return hose. (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION.)

7. Remove the No.1 engine mount rubber. (See ENGINE REMOVAL/INSTALLATION [ZY, Z6].)

8. Loosen the exhaust manifold insulator bolts.

9. Move the exhaust manifold insulator slightly out of the way and loosen the exhaust manifold nuts.

10. Remove the installation bolts of the front stabilizer and front crossmember component. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

11. Loosen the front crossmember component installation bolts and lower the front crossmember component approx. 100 mm {3.94 in}. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

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

13. Remove the exhaust manifold together with the insulator by lowering it to the underside of the vehicle.

Exhaust Manifold Installation Note

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

EGR Pipe Installation Note

1. Tighten the EGR pipe bolts and nuts in the order shown in the figure.