626 1999-2001

Exhaust Manifold

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Removal & Installation



2.0L (Fs) Engine

Specific to:

Mazda 626 1999-2002

Mazda Protege 2001-2003

Mazda Protege5 2002-2003



Click image to see an enlarged view

Fig. Exploded view of the exhaust system-626 shown, Protégé similar

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust manifold insulator
     
    Oxygen Sensor (O 2 S) electrical connector
     
    O 2 S, if necessary
     
    Exhaust Gas Recirculation (EGR) pipe, if equipped
     
    Exhaust pipe flange nuts
     
    Exhaust pipe from the manifold
     
    Exhaust manifold
     

  4.  

To install:

  1. Be sure all gasket mating surfaces are clean prior to assembly.
  2.  
  3. Install or connect the following:

    Exhaust manifold using a new gasket. Torque the bolts to 22 ft. lbs. (30 Nm) and the nuts to 20 ft. lbs. (28 Nm).
     
    Exhaust pipe flange using a new gasket. Torque the nuts to 38 ft. lbs. (51 Nm).
     
    EGR pipe, if equipped
     
    O 2 S, if necessary
     
    O 2 S electrical connector
     
    Exhaust manifold insulator
     
    Negative battery cable
     

  4.  

2.5L Engine

Specific to:

Mazda 626 1999-2002

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Both pipes must be disconnected, even if only one manifold is to be removed.



    Negative battery cable
     
    Oxygen (O 2 S) sensor connectors
     
    Front and rear exhaust pipe nuts and lower the exhaust system
     



    Exhaust Gas Recirculation (EGR) pipe, if equipped; if removing the rear (right side) manifold
     
    Heat shield
     
    2 nuts and 5 bolts and the exhaust manifold
     

  4.  

To install:

  1. Clean all gasket mating surfaces.
  2.  
  3. Install or connect the following:

    Exhaust manifold using a new gasket. Torque the nuts and bolts to 12-22 ft. lbs. (16-22 Nm).
     
    Heat shield. Torque the bolts to 95 inch lbs. (11 Nm).
     
    EGR pipe, if equipped; if installing the rear (right side) manifold
     
    Exhaust pipes using new gaskets. Torque the nuts to 38 ft. lbs. (51 Nm).
     
    O 2 S connectors
     
    Negative battery cable
     

  4.  

 
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