Mazda B-Series 1998-06

Exhaust Manifold

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Removal & Installation




CAUTION
Allow the engine to cool before attempting to remove the manifolds. Serious injury can result from contact with hot exhaust manifolds.

2.3L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust flange nuts
     
    Drive belt
     
    Coolant
     
    Upper radiator hose and the engine reservoir hose
     
    A/C compressor
     
    Heater hose
     
    Oil indicator and the upper bolt for the tube assembly
     
    Lower bolt and remove the oil indicator tube assembly
     
    Front radiator tube
     

  4.  
  5. Remove the pushpins and position the right inner fender splash shield out of the way.
  6.  
  7. Remove or disconnect the following:

    Alternator electrical connectors
     
    Lower front end accessory drive (FEAD) mounting bolts
     
    Upper mounting bolt and the FEAD assembly
     
    Two nuts and position the coolant tube out of the way
     
    Exhaust manifold
     
    Exhaust manifold gasket
     

  8.  

To install:

  1. Install or connect the following:

    Exhaust manifold gasket
     
    Exhaust manifold and the nuts
     
    Coolant tube and the nuts
     
    FEAD assembly and the upper mounting bolts
     
    Lower FEAD mounting bolts
     
    Alternator electrical connectors
     
    Right inner splash shield and pushpins
     
    Upper radiator tube and install the bolts
     
    Oil indicator tube assembly and the lower bolt
     
    Oil indicator tube upper bolt and the oil indicator
     
    Heater water hose
     
    A/C compressor
     
    Upper radiator hose and the engine reservoir hose
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Install the serpentine drive belt.
  6.  
  7. Install the exhaust flange nuts.
  8.  
  9. Connect the battery ground cable.
  10.  



Click image to see an enlarged view

Fig. Exhaust manifold and related components-2.3L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.

  4.  
  5. Remove or disconnect the following:

    Exhaust flange nuts
     
    Drive belt
     
    Coolant
     
    Upper radiator hose and the engine reservoir hose
     
    Air conditioning compressor
     
    Heater hose
     
    Oil indicator and the upper bolt for the tube assembly
     
    Lower bolt and remove the oil indicator tube assembly
     
    Front radiator tube
     

  6.  
  7. Remove the pushpins and position the right inner fender splash shield out of the way.
  8.  
  9. Remove or disconnect the following:

    Alternator electrical connectors
     
    Lower front end accessory drive (FEAD) mounting bolts
     
    Upper mounting bolt and the FEAD assembly
     
    Two nuts and position the coolant tube out of the way
     
    Exhaust manifold
     
    Exhaust manifold gasket
     

  10.  

To install:

  1. Install or connect the following:

    Exhaust manifold gasket
     
    Exhaust manifold and the nuts
     
    Coolant tube and the nuts
     
    FEAD assembly and the upper mounting bolts, finger tight.
     
    Lower FEAD mounting bolts, finger tight. Then, torque all FEAD bolts, in the sequence shown, to 35 ft. lbs. (47 Nm).
     
    Alternator electrical connectors
     
    Right inner splash shield and pushpins
     
    Upper radiator tube and install the bolts
     
    Oil indicator tube assembly and the lower bolt
     
    Oil indicator tube upper bolt and the oil indicator
     
    Heater water hose
     
    Air conditioning compressor
     
    Upper radiator hose and the engine reservoir hose
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Install the serpentine drive belt.
  6.  
  7. Install the exhaust flange nuts.
  8.  
  9. Connect the battery ground cable.
  10.  

2.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Intake Air Temperature (IAT) sensor
     
    Air cleaner outlet tube
     
    Differential Pressure Feedback (DPFE) sensor and move it aside
     
    Exhaust Gas Recirculation (EGR) transducer lines at the tube
     
    Loosen and remove the EGR valve-to-exhaust manifold tube
     
    Catalytic converter from the exhaust manifold
     
    Rear engine lifting eye nuts
     
    Exhaust manifold and discard the gasket
     

  4.  

To install:

Click image to see an enlarged view

Fig. Tighten the exhaust manifold bolts in 2 stages

  1. Clean the mating surfaces on the exhaust manifold and the cylinder head.
  2.  
  3. Install a new gasket and the exhaust manifold. Torque the bolts in sequence as follows:
    1. 16 ft. lbs. (23 Nm).
    2.  
    3. 59 ft. lbs. (80 Nm).
    4.  

  4.  
  5. Install or connect the following:

    Rear engine lifting eye. Torque the bolts to 15 ft. lbs. (20 Nm).
     
    Catalytic converter to the exhaust manifold
     
    EGR valve to the exhaust manifold tube
     
    EGR transducer lines
     
    DPFE sensor
     
    Air cleaner outlet tube
     
    IAT sensor
     
    Negative battery cable
     

  6.  
  7. Start the vehicle and check for leaks, repair if necessary.
  8.  

3.0L Engine
Left Manifold
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Install or connect the following:

    Negative battery cable
     
    Exhaust flange nuts
     
    Exhaust Gas Recirculation (EGR) valve from the exhaust manifold tube
     
    Oil lever indicator and bracket
     
    Exhaust manifold and discard the gasket
     

  4.  

To install:

Click image to see an enlarged view

Fig. Tighten the exhaust manifold bolts in sequence-3.0L left side

  1. Clean the mating surfaces for the exhaust manifold and cylinder head.
  2.  
  3. Install a new gasket and the exhaust manifold. Torque the bolts in sequence to:
    1. 89 inch lbs. (10 Nm).
    2.  
    3. 15 ft. lbs. (20 Nm).
    4.  

  4.  
  5. Install or connect the following:

    Oil lever indicator tube and bracket. Torque the bolt to 12 ft. lbs. (16 Nm).
     
    EGR valve to the exhaust manifold tube. Torque the fastener to 26 ft. lbs. (35 Nm).
     
    Exhaust flange. Torque the nuts to 25 ft. lbs. (34 Nm).
     
    Negative battery cable
     

  6.  
  7. Start the vehicle and check for leaks, repair if necessary.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.

  4.  
  5. Install or connect the following:

    Exhaust flange nuts
     
    Exhaust Gas Recirculation (EGR) valve from the exhaust manifold tube
     
    Oil lever indicator and bracket
     
    Exhaust manifold and discard the gasket
     

  6.  

To install:

Click image to see an enlarged view

Fig. Left side exhaust manifold bolt torque sequence-3.0L engine

  1. Clean the mating surfaces for the exhaust manifold and cylinder head.
  2.  
  3. Install a new gasket and the exhaust manifold. Torque the bolts in sequence to:
    1. 89 inch lbs. (10 Nm).
    2.  
    3. 15 ft. lbs. (20 Nm).
    4.  

  4.  
  5. Install or connect the following:

    Oil lever indicator tube and bracket. Torque the bolt to 12 ft. lbs. (16 Nm).
     
    EGR valve to the exhaust manifold tube. Torque the fastener to 26 ft. lbs. (35 Nm).
     
    Exhaust flange. Torque the nuts to 25 ft. lbs. (34 Nm).
     
    Negative battery cable
     

  6.  
  7. Start the vehicle and check for leaks, repair if necessary.
  8.  

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

    Negative battery cable
     
    Exhaust manifold flange
     
    Ignition coil support bracket
     
    Exhaust manifold and discard the gasket
     

  4.  

To install:

Click image to see an enlarged view

Fig. Tighten the right side exhaust manifold bolts in the proper sequence-3.0L

  1. Clean the mating surfaces for the exhaust manifold and cylinder head
  2.  
  3. Install a new gasket and the exhaust manifold. Torque the bolts is sequence to:
    1. 89 inch lbs. (10 Nm).
    2.  
    3. 18 ft. lbs. (25 Nm).
    4.  

  4.  
  5. Install or connect the following:

    Ignition coil support bracket. Torque the bolts to 15 ft. lbs. (20 Nm).
     
    Exhaust flange nuts. Torque the nuts to 33 ft. lbs. (46 Nm).
     
    Negative battery cable
     

  6.  
  7. Start the vehicle and check for leaks, repair if necessary.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.

  4.  
  5. Remove or disconnect the following:

    Exhaust manifold flange
     
    Ignition coil support bracket
     
    Exhaust manifold and discard the gasket
     

  6.  

To install:

Click image to see an enlarged view

Fig. Right side exhaust manifold bolt torque sequence-3.0L engine

  1. Clean the mating surfaces for the exhaust manifold and cylinder head
  2.  
  3. Install a new gasket and the exhaust manifold. Torque the bolts is sequence to:
    1. 89 inch lbs. (10 Nm).
    2.  
    3. 18 ft. lbs. (25 Nm).
    4.  

  4.  
  5. Install or connect the following:

    Ignition coil support bracket. Torque the bolts to 15 ft. lbs. (20 Nm).
     
    Exhaust flange nuts. Torque the nuts to 33 ft. lbs. (46 Nm).
     
    Negative battery cable
     

  6.  
  7. Start the vehicle and check for leaks, repair if necessary.
  8.  

4.0L Engine
Left Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.

  4.  
  5. Raise and support the vehicle safely. Remove the exhaust pipe flange retaining bolts.
  6.  
  7. Lower the vehicle. Disconnect the Differential Pressure Feedback EGR (DPFE) transducer hoses. Disconnect the EGR valve to exhaust manifold tube.
  8.  
  9. Disconnect the EGR valve to exhaust manifold tube from the EGR valve and remove the EGR valve to exhaust manifold tube.
  10.  
  11. Remove the exhaust manifold retaining nuts. Remove the exhaust manifold from the engine.
  12.  

To install:

Click image to see an enlarged view

Fig. Left side exhaust manifold bolt torque sequence-4.0L engine

  1. Clean the mating surfaces for the exhaust manifold and cylinder head
  2.  
  3. Install a new gasket and the exhaust manifold. Torque the bolts to specification.
  4.  
  5. Continue the installation in the reverse order of the removal procedure.
  6.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.

  4.  
  5. Raise and support the vehicle safely. Remove the exhaust pipe flange retaining bolts.
  6.  
  7. Lower the vehicle.
  8.  
  9. Remove the exhaust manifold retaining nuts. Remove the exhaust manifold from the engine.
  10.  

To install:

Click image to see an enlarged view

Fig. Right side exhaust manifold bolt torque sequence-4.0L engine

  1. Clean the mating surfaces for the exhaust manifold and cylinder head
  2.  
  3. Install a new gasket and the exhaust manifold. Torque the bolts to specification.
  4.  
  5. Continue the installation in the reverse order of the removal procedure.
  6.  

4.0L OHV Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Oil level indicator tube and bracket
     
    Exhaust pipe-to-manifold bolts
     
    Power steering pump hoses, if removing the left-hand manifold
     
    Hot air intake shroud that is bolted around the manifold, if removing the right-hand manifold
     
    Exhaust manifold and gasket
     

  4.  

To install:

  1. Clean all mating surfaces for the exhaust manifold and cylinder head.
  2.  
  3. Install or connect the following:

    New gasket and the exhaust manifold. Torque the right side bolts to 18 ft. lbs. (25 Nm) and the left side bolts to 16 ft. lbs. (22 Nm).
     
    Exhaust pipe to the manifold
     
    Oil level bracket. Torque the bolt to 17 ft. lbs. (23 Nm).
     
    Negative battery cable
     

  4.  
  5. Start the vehicle and check for leaks, repair if necessary.

    Click image to see an enlarged view

    Fig. Tighten the right side exhaust manifold in sequence



    Click image to see an enlarged view

    Fig. Tighten the left side exhaust manifold in sequence

  6.  

4.0L SOHC Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust inlet pipe-to-manifold attaching bolts
     
    Differential Pressure Feedback EGR (DPFE) transducer hoses, left side manifold only
     
    Exhaust Gas Recirculation (EGR) tube from the manifold and valve, left side manifold only
     
    Exhaust manifold and discard the gasket
     

  4.  

To install:

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

    New gasket and the exhaust manifold. Torque the bolts to 16 ft. lbs. (22 Nm).
     
    EGR tube to the manifold. Torque the fastener to 30 ft. lbs. (40 Nm) left side manifold only
     
    DPFE transducer hoses, left side manifold only
     
    Exhaust inlet pipe-to-manifold attaching bolts. Torque the bolts to 30 ft. lbs. (40 Nm).
     
    Negative battery cable
     

  4.  
  5. Start the vehicle and check for leaks, repair if necessary.
  6.  

 
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