Exhaust System: Service and Repair

EXHAUST SYSTEM REMOVAL/INSTALLATION [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. Removal and Replacement

2. Disconnect the negative battery cable. Removal and Replacement

3. Remove the plug hole plate. Service and Repair

4. Remove in the order indicated in the table.

5. Remove the exhaust system insulator.

6. Install in the reverse order of removal.









Exhaust System Insulator Removal/installation Note

1. Remove the member.






2. Remove the exhaust system insulator in the order shown in the figure.

3. Install in the reverse order of removal.









Insulator (No.3) removal note

1. Remove the protector.





2. Remove the Insulator (No.3).

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 engine hanger.





2. Remove the exhaust manifold insulator.

Exhaust Manifold Removal Note

CAUTION:
- Avoid bending the flexible pipe over in removing the exhaust manifold. Otherwise, the pipe could be damaged and consequently leakage might occur. Be sure to cover the pipe with cardboard or equivalent when removing the exhaust manifold.

1. Remove the air cleaner. Service and Repair

2. Remove the windshield wiper arm and blade. Windshield Wiper Arm And Blade Removal/Installation

3. Remove the cowl grille. Cowl Grille Removal/Installation

4. Remove the cowl panel. Cowl Panel Removal/Installation

5. Cover the windshield glass with tape to protect it from damages.






6. Remove the No.1 brake fluid reserve tank installation nut as shown in the figure.






7. Put the No.1 brake fluid reserve tank aside with its hose connected so it won't get in the way of work.

8. Remove the generator duct. Removal and Replacement

9. Remove the aerodynamic under cover. Service and Repair

10. Remove the No.1 engine mount. Removal and Replacement

11. Cover the flexible pipe on the exhaust manifold with cardboard without bending it as shown in the figure.






12. Loosen the exhaust manifold installation nut.

13. Install the SST using the following procedure.

CAUTION:
- Refer to the SST instruction manual for the basic handing procedure.





- As shown in the figure, set the rear shafts of the SST to the left and right shock absorber bolts.





- Install front foot No.2 to the left/right front shaft of the SST, then align the groove of the front shaft of the SST with the folded up part of the vehicle as shown in the figure.





- Adjust the positions of the SST side bars so that they are the same height (left and right) and horizontal. Make sure each joint is securely tightened.






14. Remove the No.3 engine mount installation bolt (body side). Removal and Replacement

15. Remove the body ground as shown in the figure.






16. Cover the frame with tape.






17. Hang the engine as shown in the figure.






18. Move the engine toward the vehicle front as shown in the figure.






19. Put the engine slowly so that the No.3 engine mount is placed as shown in the figure.






20. Remove the chain of the SST.

21. Remove the exhaust manifold.

Exhaust Manifold Installation Note

1. Temporarily tighten the new exhaust manifold installation nuts.

2. Tighten the nuts in the order shown in the figure.






Tightening torque
- 43-64 Nm {4.4-6.5 kgf-m, 32-47 ft-lbf}

Main Silencer Installation Note

1. Spray the flare with a carbon remover (equivalent to TB6601). (Only in the case of reusing the main silencer)






2. Remove the carbon adhering to the flared section shown in the figure using a nylon brush or sandpaper (No.400 or equivalent). (Only in the case of reusing the main silencer)