Mazda 2: Exhaust System

EXHAUST SYSTEM INSPECTION

1. Start the engine and inspect each exhaust system component for exhaust gas leakage.

• If there is leakage, repair or replace the appropriate component.

  (See EXHAUST SYSTEM REMOVAL/INSTALLATION).

EXHAUST SYSTEM REMOVAL/INSTALLATION

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 BATTERY REMOVAL/INSTALLATION).

2. Remove in the order indicated in the table.

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

4. Install in the reverse order of removal.

1. Main silencer
2. Tunnel member
3. TWC
4. Seal ring
5. A/F sensor
6. Exhaust manifold insulator
7. HO2S
8. Exhaust manifold bracket
9. Insulator
10. WU-TWC insulator
11. Exhaust manifold
12. Exhaust manifold gasket

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.

1. Insulator No.3
2. Insulator No.2
3. Insulator No.1

Seal Ring Removal Note

1. Remove the seal ring using a flathead screwdriver being careful not to damage the pipe.

Exhaust Manifold Insulator Removal Note

1. Remove the air cleaner cover and air cleaner case. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION).

2. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT).

3. Remove the EGR pipe (exhaust manifold side). (See EGR PIPE REMOVAL/INSTALLATION).

4. Remove the EGR valve and EGR valve bracket as a single unit.

5. Remove the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION).

6. Remove the cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION).

7. Remove the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION).

8. Remove the windshield wiper motor. (See WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION).

9. Remove the exhaust manifold insulator.

Exhaust Manifold Removal Note

1. Disconnect the ventilation hose (cylinder head cover side).

2. Disconnect the ignition coil connector.

3. Set the ignition coil harness out of the way.

4. Remove the exhaust manifold.

Exhaust Manifold Installation Note

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

Seal Ring Installation Note

CAUTION:

• 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.

2. Install the SST to the seal ring so that the SST is even with the flange.

3. Press in the seal ring by tapping the SST using a plastic hammer until the seal ring contacts the flange.

TWC Installation Note

1. Spray carbon remover (TB6601 or equivalent) on the flared section of the exhaust pipe.

2. Remove the carbon adhering to the flared section shown in the figure using a nylon brush or sandpaper (No. 400 or equivalent).

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