EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 1.8, 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.

Caution

•  If the middle pipe, TWC, or exhaust manifold is reused, sand the flange surface and remove sanding residue, accumulated matter, and friction marks before installing the seal ring.

•  If this work is not performed, the seal ring may not be installed correctly. When sanding the flange surface, be careful not to damage the surface.

•  When sanding the flange surface, sanding residue may get into the removed part or pipe resulting in deterioration or damage to the part. When sanding, make sure parts are protected from sanding residue or foreign matter penetration.

1.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)

2.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)

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.

MZR 1.8, MZR 2.0

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1	Main silencer
2	Middle pipe (See Flange Surface Installation Note)
3	Seal ring (rear side) (See Seal Ring Removal Note.) (See Seal Ring (Rear Side) Installation Note.)
4	Tunnel member
5	HO2S (See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)
6	A/F sensor (See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)
7	TWC (See Flange Surface Installation Note)
8	Seal ring (front side) (See Seal Ring Removal Note.) (See Seal Ring (Front Side) Installation Note.)
9	Exhaust manifold bracket (See Exhaust Manifold Bracket Removal Note.)
10	Exhaust manifold upper insulator (See Exhaust Manifold Upper Insulator Installation Note (MZR 1.8, MZR 2.0))
11	Exhaust manifold (See Flange Surface Installation Note) (See Exhaust Manifold Installation Note)
12	Exhaust manifold gasket
13	Exhaust manifold lower insulator
14	Tailpipe garnish (See Tailpipe Garnish Replacement Note)

MZR 2.5

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1	Main silencer
2	Middle pipe (See Flange Surface Installation Note)
3	Seal ring (rear side) (See Seal Ring Removal Note.) (See Seal Ring (Rear Side) Installation Note.)
4	HO2S (See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)
5	TWC (See Flange Surface Installation Note)
6	Seal ring (front side) (See Seal Ring Removal Note.) (See Seal Ring (Front Side) Installation Note.)
7	A/F sensor (See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)
8	Exhaust manifold bracket (See Exhaust Manifold Bracket Removal Note.)
9	Exhaust manifold upper insulator (See Exhaust Manifold Upper Insulator Installation Note (MZR 2.5))
10	Exhaust manifold (See Flange Surface Installation Note) (See Exhaust Manifold Installation Note)
11	Exhaust manifold gasket
12	Tunnel member
13	Tailpipe garnish (See Tailpipe Garnish Replacement Note)

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 (front)
2	Insulator (middle)
3	Insulator (rear) (See Insulator (rear) Removal Note.)

Insulator (rear) Removal Note

Note

•  The insulator (rear) is installed using rivets.

•  When resin stalling the rivet, install the same rivet or M5 bolt and nut.

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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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 Bracket Removal Note

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

2.  Remove the exhaust manifold bracket.

Tailpipe Garnish Replacement Note

Note

•  Only the tailpipe garnish can be replaced using the following procedure if it has been damaged (for Europe only).

1.  Remove the spot welding on the damaged tailpipe garnish.

2.  Install a new tailpipe garnish as shown in the figure.

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Flange Surface Installation Note

Caution

•  If the middle pipe, TWC, or exhaust manifold is reused, sand the flange surface and remove sanding residue, accumulated matter, and friction marks before installing the seal ring.

•  If this work is not performed, the seal ring may not be installed correctly. When sanding the flange surface, be careful not to damage the surface.

•  When sanding the flange surface, sanding residue may get into the removed part or pipe resulting in deterioration or damage to the part. When sanding, make sure parts are protected from sanding residue or foreign matter penetration.

1.  Sand the surface shown in the figure using sandpaper and remove sanding residue, accumulated matter, and friction marks.

2.  Degrease the sanded surface.

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Exhaust Manifold Installation Note

1.  Temporarily tighten the exhaust manifold installation nuts.

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

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Exhaust Manifold Upper Insulator Installation Note (MZR 1.8, MZR 2.0)

1.  Temporarily tighten the exhaust manifold insulator.

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

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Exhaust Manifold Upper Insulator Installation Note (MZR 2.5)

1.  Temporarily tighten the exhaust manifold insulator.

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

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Seal Ring (Front Side) Installation Note

Caution

•  If the TWC, or exhaust manifold is reused, sand the flange surface and remove sanding residue, accumulated matter, and friction marks before installing the seal ring. If this work is not performed, the seal ring may not be installed correctly. (See Flange Surface Installation Note.)

•  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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Seal Ring (Rear Side) Installation Note

Caution

•  If the middle pipe or TWC is reused, sand the flange surface and remove sanding residue, accumulated matter, and friction marks before installing the seal ring. If this work is not performed, the seal ring may not be installed correctly. (See Flange Surface Installation Note.)

•  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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