Mazda 3 Service Manual: Exhaust System Removal/Installation [Mzr 2.0, Mzr 2.5]

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..

2. Disconnect the negative battery cable..

3. Remove the plug hole plate..

4. Remove in the order indicated in the table.

5. Remove the insulator..

6. Install in the reverse order of removal.

MZR 2.0

MZR 2.5 (Except for Mexico)

MZR 2.5 (Mexico)

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.

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).

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

Insulator (Front) Removal Note

1. Remove the tunnel member (front).

2. Remove the insulator (front).

Exhaust Manifold Removal Note

1. Windshield wiper arm and blade..

2. Remove the cowl grille..

3. Remove the windshield wiper motor..

4. Remove the cowl panel..

5. Remove the exhaust manifold.

Exhaust Manifold Installation Note

1. Temporarily tighten the exhaust manifold installation nuts.

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

Tightening torque

• 43—64 N·m {4.4—6.5 kgf·m, 32—47 ft·Ibf}

Exhaust Manifold Insulator Installation Note

1. Temporarily tighten the exhaust manifold insulator.

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

MZR 2.0

MZR 2.5

Tightening torque

• 8—10 N·m {82—101 kgf·cm, 71—88 in·Ibf}