EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 1.6]

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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.  Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [MZR 1.6].)

2.  Remove in the order indicated in the table.

3.  Remove the exhaust system insulator. (See Exhaust System Insulator Removal/Installation.)

4.  Install in the reverse order of removal.

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1	insulator
2	A/F sensor (See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [MZR 1.6].)
3	Insulator
4	Plate
5	Exhaust manifold (See Exhaust Manifold Removal Note.) (See Exhaust Manifold Installation Note.)
6	Exhaust manifold gasket
7	Tunnel member
8	Brace bar (See Brace Bar Removal Note.)
9	HO2S (See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [MZR 1.6].)
10	Presilencer
11	Main silencer

Exhaust System Insulator Removal/Installation

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) (See Insulator (rear) removal note.)
2	Insulator (middle)
3	Insulator (front)

Insulator (rear) removal note

Note

•  The insulator (rear) 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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Exhaust Manifold Removal Note

1.  Disconnect the ignition coil connector and set the wiring harness aside.

2.  Remove the exhaust manifold.

Brace Bar Removal Note

1.  Remove the floor under cover. (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

2.  Remove the brace bar.

Exhaust Manifold Installation Note

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

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