Home

Mazdamanuals.com

EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))]

EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))]

 id0115u3800200

Replacement Part

Gasket
 
Quantity: 1
 
Location of use: Main silencer
Nut
 
Quantity: 4
 
Location of use: TWC
Exhaust manifold gasket
 
Quantity: 1
 
Location of use: Exhaust manifold
Gasket
 
Quantity: 1
 
Location of use: Exhaust manifold
Nut
 
Quantity: 5
 
Location of use: Exhaust manifold (WU-TWC)
—

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.

2WD

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION [(E)].)

2.  Remove the floor under cover No.1 (RH). (With Mazda M Hybrid) (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

3.  Remove in the order indicated in the table.

4.  Remove the insulator. (See Exhaust Manifold Insulator Removal Note.)

5.  Install in the reverse order of removal.

Step 1

ac30zw00002256

1
Main silencer
(See TAILPIPE REPLACEMENT [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
2
Tunnel cover
(See Tunnel Cover Installation Note.)
3
Brace bar
(See Brace Bar Installation Note.)
4
Tunnel member
(See Tunnel Member Installation Note.)
5
Connector
6
TWC component
(See TWC component Removal Note.)
7
HO2S
(See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
8
Exhaust shutter valve connector
9
TWC

Step 2

ac30zw00002257

1
A/F sensor
(See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
2
Clip
3
Insulator
4
Exhaust manifold insulator
(See Exhaust Manifold Insulator Removal Note.)
(See Exhaust Manifold Insulator Installation Note.)
5
Exhaust manifold (WU-TWC)
(See Exhaust Manifold Removal Note.)
(See Exhaust Manifold Installation Note.)
6
Exhaust manifold gasket


Exhaust system insulator removal/installation

1.  Remove the floor under cover No.1 (RH). (Without Mazda M Hybrid) (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

2.  Remove the floor under cover No.2. (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

3.  Remove the Mazda M hybrid battery. (With Mazda M Hybrid) (See Mazda M Hybrid BATTERY REMOVAL/INSTALLATION.)

4.  Remove in the order indicated in the table.

5.  Install in the reverse order of removal.

ac30zw00002258

1
Insulator (rear)
(See Insulator (Rear) Installation Note.)
2
Insulator (front)
(See Insulator (front) Installation Note.)
3
Insulator (middle)
(See Insulator (middle) Installation Note.)


TWC component Removal Note

1.  Remove the floor under cover No.1 (LH). (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

2.  Remove the TWC component.


Exhaust Manifold Insulator Removal Note

1.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

2.  Remove the bolts shown in the figure. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

ac5wzw00010681

3.  Disconnect the wiring harness clip shown in the figure.

ac5wzw00010682

4.  Set the purge solenoid valve component aside so that it does not interfere with the servicing.

ac5wzw00010695

5.  Remove the insulators shown in the figure.

am3zzw00031802

6.  Remove the exhaust manifold insulator.


Exhaust Manifold Removal Note

Note
•  When removing the exhaust manifold, the bracket installed under the exhaust manifold does not have to be removed. Remove the exhaust manifold with the bracket installed.

1.  Remove the front crossmember. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [(E)].)

2.  Remove the exhaust manifold.


Exhaust Manifold Installation Note

1.  Temporarily tighten the exhaust manifold installation nuts (1) and (2) shown in the figure by hand.

ac5uuw00002679

2.  Tighten the exhaust manifold installation nuts (1) and (2) shown in the figure.

am3zzw00032167

3.  Temporarily tighten the exhaust manifold installation nuts (3) to (5) shown in the figure by hand.

ac5wzw00002715

4.  Tighten the exhaust manifold installation nuts (3) to (5) shown in the figure.

5.  Tighten the exhaust manifold installation nuts (1) and (2) shown in the figure.

6.  Temporarily tighten the bolts (6) and (7) shown in the figure.

ac5wzw00010633

7.  Tighten the bolt (6) shown in the figure.

8.  Tighten the bolt (7) shown in the figure.

9.  Install the front crossmember. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [(E)].)


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.

ac5wzw00010634

3.  Install the insulators shown in the figure.

am3zzw00031802

4.  Install the purge solenoid valve component.

ac5wzw00010695

5.  Install the wiring harness clip shown in the figure.

ac5wzw00010682

6.  Install the bolts shown in the figure. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

ac5wzw00010681

7.  Install the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)


AWD

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION [(E)].)

2.  Remove the floor under cover No.1 (RH). (With Mazda M Hybrid) (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

3.  Remove in the order indicated in the table.

4.  Remove the insulator. (See Exhaust system insulator removal/installation.)

5.  Install in the reverse order of removal.

Step 1

ac30zw00002264

1
Main silencer
(See TAILPIPE REPLACEMENT [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
2
Tunnel cover
(See Tunnel Cover Installation Note.)
3
Brace bar
(See Brace Bar Installation Note.)
4
Tunnel member
(See Tunnel Member Installation Note.)
5
Connector
6
TWC component
(See TWC component Removal Note.)
7
HO2S
(See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
8
Exhaust shutter valve connector
9
TWC

Step 2

ac30zw00002257

1
A/F sensor
(See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
2
Clip
3
Insulator
4
Exhaust manifold insulator
(See Exhaust Manifold Insulator Removal Note.)
(See Exhaust Manifold Insulator Installation Note.)
5
Exhaust manifold (WU-TWC)
(See Exhaust Manifold Removal Note.)
(See Exhaust Manifold Installation Note.)
6
Exhaust manifold gasket


Exhaust system insulator removal/installation

1.  Remove the floor under cover No.1 (RH). (Without Mazda M Hybrid) (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

2.  Remove the floor under cover No.2. (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

3.  Remove the Mazda M hybrid battery. (With Mazda M Hybrid) (See Mazda M Hybrid BATTERY REMOVAL/INSTALLATION.)

4.  Remove the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION [(E)].)

5.  Remove in the order indicated in the table.

6.  Install in the reverse order of removal.

ac30zw00002265

1
Insulator (rear)
(See Insulator (Rear) Installation Note.)
2
Insulator (front)
(See Insulator (front) Installation Note.)
3
Insulator (middle)
(See Insulator (middle) Installation Note.)


TWC component Removal Note

1.  Remove the floor under cover No.1 (LH). (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

2.  Remove the TWC component.


Exhaust Manifold Insulator Removal Note

1.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

2.  Remove the bolts shown in the figure. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

ac5wzw00010681

3.  Disconnect the wiring harness clip shown in the figure.

ac5wzw00010682

4.  Set the purge solenoid valve component aside so that it does not interfere with the servicing.

ac5wzw00010695

5.  Remove the insulators shown in the figure.

am3zzw00031802

6.  Remove the exhaust manifold insulator.


Exhaust Manifold Removal Note

Note
•  When removing the exhaust manifold, the bracket installed under the exhaust manifold does not have to be removed. Remove the exhaust manifold with the bracket installed.

1.  Remove the front crossmember. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [(E)].)

2.  Remove the exhaust manifold.


Exhaust Manifold Installation Note

1.  Temporarily tighten the exhaust manifold installation nuts (1) and (2) shown in the figure by hand.

ac5uuw00002679

2.  Tighten the exhaust manifold installation nuts (1) and (2) shown in the figure.

am3zzw00032167

3.  Temporarily tighten the exhaust manifold installation nuts (3) to (5) shown in the figure by hand.

ac5wzw00002715

4.  Tighten the exhaust manifold installation nuts (3) to (5) shown in the figure.

5.  Tighten the exhaust manifold installation nuts (1) and (2) shown in the figure.

6.  Temporarily tighten the bolts (6) and (7) shown in the figure.

ac5wzw00010633

7.  Tighten the bolt (6) shown in the figure.

8.  Tighten the bolt (7) shown in the figure.

9.  Install the front crossmember. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [(E)].)


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.

ac5wzw00010634

3.  Install the insulators shown in the figure.

am3zzw00031802

4.  Install the purge solenoid valve component.

ac5wzw00010695

5.  Install the wiring harness clip shown in the figure.

ac5wzw00010682

6.  Install the bolts shown in the figure. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

ac5wzw00010681

7.  Install the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)


Insulator (middle) Installation Note

1.  Align the stud bolts shown in the figure with the insulator (middle) and install.

2WD

ac30zw00002259

AWD

ac30zw00002266

2.  Tighten the nuts to the specified torque.


Insulator (front) Installation Note

1.  Align the stud bolts shown in the figure with the insulator (front) and install.

am3zzw00021241

2.  Install the fasteners.

3.  Tighten the nuts to the specified torque.


Insulator (Rear) Installation Note

1.  Align the stud bolt shown in the figure with the insulator (rear) and install.

ac30zw00002260

2.  Tighten the nuts to the specified torque.


Tunnel Member Installation Note

1.  Tighten bolt A shown in the figure to the specified torque.

With Mazda M Hybrid

ac30zw00004652

Without Mazda M Hybrid

ac30zw00004653

2.  Tighten bolt B shown in the figure to the specified torque.

3.  Tighten the remaining bolts and nuts to the specified torque.


Brace Bar Installation Note

1.  Tighten bolt A shown in the figure to the specified torque.

With Mazda M Hybrid

ac30zw00004654

Without Mazda M Hybrid

ac30zw00004655

2.  Tighten bolt B shown in the figure to the specified torque.

3.  Tighten the remaining bolts to the specified torque.


Tunnel Cover Installation Note

1.  Align the stud bolt shown in the figure with the tunnel cover and install.

ac30zw00002263

2.  Install fastener A shown in the figure.

3.  Install the remaining fasteners.

4.  Tighten the bolts shown in the figure to the specified torque.

5.  Tighten the nuts shown in the figure to the specified torque.