Mazda 323/626/929/GLC/MX-6/RX-7 1978-1989

Muffler

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REMOVAL & INSTALLATION



GLC

The GLC muffler assembly is attached at the front via a flange, and at the rear via a clamped pipe connection.

  1. Raise and safely support the front end on jackstands.
  2.  
  3. Unbolt the clamp at the rear, then slide it forward and away from the connection.
  4.  
  5. Remove the nuts from the rear side of the flange at the front.
  6.  
  7. Support the assembly, then pull the bolts forward and out of the flange at the front.
  8.  
  9. Remove the donut type hangers at the front and pull the rear hangers off the support prongs.
  10.  
  11. Turn the assembly back and forth, then pull the rear pipe out of the connector for the rear pipe and remove it.
  12.  
  13. Unbolt the halves of the heat shield from the front pipe and install it onto the new assembly.
  14.  
  15. Remove the gasket from the flange at the front and replace it during reassembly.
  16.  
  17. Installation is the reverse of removal. Make sure that all parts have sufficient clearance from underbody members, before tightening the clamps.
  18.  

323
  1. Raise and safely support the front end on jackstands.
  2.  
  3. Remove the nuts from the flange connecting the resonator rear pipe and muffler inlet pipe.
  4.  

See Figures 1, 2 and 3

Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the 323 exhaust system (non-turbo shown)

  1. Pull the bolts out at the front.
  2.  
  3. Disconnect the hangers from the prongs at the front and rear of the muffler, and at the rear of the tail pipe, then remove the assembly. On the Hatchback only, unclamp and remove the tail pipe, and install it on the new assembly.
  4.  
  5. Installation is the reverse of removal. Make sure that all parts have sufficient clearance from underbody members, before tightening the clamps.
  6.  

626/MX-6 and 929

The muffler or main silencer assembly is flanged at the front. The muffler configuration is the same for both 626/MX-6 turbo and non-turbo models.

  1. Raise and safely support the rear end on jackstands.
  2.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the 1983-89 626 exhaust system (non-turbo shown)

  1. Remove the nuts and bolts connecting the muffler at the flange. Then, on gasoline engine vehicles, unhook the hangers at the prongs and remove the assembly. On diesel-equipped vehicles, unhook the donut type rubber connectors at the front and outboard on the rear support.
  2.  
  3. Installation is the reverse of removal. If the rubber hangers are broken or worn, replace them. Make sure that all parts have sufficient clearance from underbody members, before tightening the clamps.
  4.  

RX-7

1979-85 models are equipped with only one muffler, as opposed to the dual muffler system used on 1986-89 RX-7s (with turbo and non-turbo engines).

  1. Raise and safely support the rear end on jackstands.
  2.  
  3. Remove the lower protective cover from the pre-monolith converter and the rear of the exhaust pipes.
  4.  
  5. Remove the main converter cover.
  6.  
  7. Disconnect the split air pipe from the muffler by removing the flange nuts.
  8.  
  9. Unhook and remove the muffler bracket rubber pieces.
  10.  
  11. Lower the muffler from the vehicle.
  12.  
  13. On dual muffler systems, remove the remaining muffler in the same manner.
  14.  
  15. Installation is the reverse of removal. Use new gaskets during installation. Make sure that all parts have sufficient clearance from underbody members, before tightening the clamps.
  16.  



Click image to see an enlarged view

Fig. Fig. 3: Dual muffler exhaust system for the 1986-89 RX-7 (turbo shown; non-tubo similar)

 
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