Mazda Car 2002-04

Exhaust Manifold

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Removal & Installation



1.5L And 1.8L (BP) Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner and air hose
     
    Water bypass pipe bolt
     
    Exhaust manifold heat shield bolts and the heat shield
     
    Oxygen (O 2 S) sensor electrical connector
     
    Exhaust pipe-to-exhaust manifold nuts and discard them
     
    Exhaust Gas Recirculation (EGR) pipe from the exhaust manifold
     
    Exhaust manifold nuts and bolts and discard the nuts
     
    Exhaust manifold
     

  4.  

To install:

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

    Exhaust manifold. Torque the bolts to 14-16 ft. lbs. (19-22 Nm) on the 1.5L engine or to 29-34 ft. lbs. (39-47 Nm) on the 1.8L engine
     
    Exhaust pipe. Torque the new nuts to 38 ft. lbs. (52 Nm)
     
    (O 2 S) connector
     
    EGR pipe. Torque the pipe to 34 ft. lbs. (47 Nm)
     
    Heat shield. Torque the bolts to 88 inch lbs. (10 Nm)
     
    Water bypass pipe. Torque the bolt to 48-65 ft. lbs. (64-89 Nm)
     
    Air hose and air cleaner
     
    Negative battery cable
     

  4.  

1.6L (Zm) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner and hose assembly
     
    Water bypass pipe-to-engine block bolt, if equipped
     
    Exhaust Gas Recirculation (EGR) pipe
     
    Oxygen Sensor (O 2 S) from the exhaust system
     
    Front exhaust pipe from the Warm-Up Three Way Catalytic (WU-TWC) converter
     
    Exhaust manifold insulator
     
    WU-TWC converter from the manifold
     
    Exhaust manifold
     

  4.  

To install:

  1. Be sure all gasket mating surfaces are clean prior to assembly.
  2.  
  3. Tighten the components following the illustration.
  4.  
  5. Install or connect the following:

    Exhaust manifold
     
    WU-TWC converter to the manifold
     
    Exhaust manifold insulator
     
    Front exhaust pipe from the WU-TWC converter
     
    O 2 S to the exhaust system
     
    EGR pipe
     
    Water bypass pipe-to-engine block bolt
     
    Air cleaner and hose assembly
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Exploded view of the exhaust system-1.6L (ZM) engines

     

  6.  

1.6L And 1.8L (FP) Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner and hose assembly
     
    Water bypass pipe-to-engine block bolt
     
    Exhaust Gas Recirculation (EGR) pipe
     
    Oxygen (O 2 S) sensor from the exhaust system
     
    Front exhaust pipe from the Warm-Up Three Way Catalytic (WU-TWC) converter
     
    Exhaust manifold insulator
     
    Warm-Up Three Way Catalytic (WU-TWC) converter from the manifold
     
    Exhaust manifold
     

  4.  

To install:

  1. Be sure all gasket mating surfaces are clean prior to assembly.
  2.  
  3. Tighten the components following the illustration.
  4.  
  5. Install or connect the following:

    Exhaust manifold
     
    Warm-Up Three Way Catalytic (WU-TWC) converter to the manifold
     
    Exhaust manifold insulator
     
    Front exhaust pipe from the Warm-Up Three Way Catalytic (WU-TWC) converter
     
    Oxygen (O 2 S) sensor to the exhaust system
     
    EGR pipe
     
    Water bypass pipe-to-engine block bolt
     
    Air cleaner and hose assembly
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Exploded view of the exhaust system-1.6L and 1.8L (FP) engines

     

  6.  

1.8L (Bp) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner and air hose
     
    Exhaust manifold heat shield bolts and the heat shield
     
    Oxygen (O 2 S) sensor electrical connector
     
    Exhaust pipe-to-exhaust manifold nuts and discard them
     
    Exhaust Gas Recirculation (EGR) pipe from the exhaust manifold
     
    Exhaust manifold nuts and bolts and discard the nuts
     
    Exhaust manifold
     

  4.  

To install:

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

    Exhaust manifold. Torque the bolts to 29-33 ft. lbs. (39-46 Nm).
     
    Exhaust pipe. Torque the new nuts to 38 ft. lbs. (52 Nm).
     
    O 2 S connector
     
    EGR pipe. Torque the pipe to 34 ft. lbs. (47 Nm).
     
    Heat shield. Torque the bolts to 95 inch lbs. (11 Nm).
     
    Air hose and air cleaner
     
    Negative battery cable
     

  4.  

1.8L (Fp) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    negative battery cable
     
    Air cleaner and hose assembly
     
    Water bypass pipe-to-engine block bolt, if equipped
     
    Exhaust Gas Recirculation (EGR) pipe
     
    Oxygen Sensor (O2S) from the exhaust system
     
    Front exhaust pipe from the Warm-Up Three Way Catalytic (WU-TWC) converter
     
    exhaust manifold insulator
     
    WU-TWC converter from the manifold
     
    Exhaust manifold
     

  4.  

To install:

  1. Be sure all gasket mating surfaces are clean prior to assembly.
  2.  
  3. Tighten the components following the illustration.
  4.  
  5. Install or connect the following:

    Exhaust manifold
     
    WU-TWC converter to the manifold
     
    exhaust manifold insulator
     
    Front exhaust pipe from the WU-TWC converter
     
    O2S to the exhaust system
     
    EGR pipe
     
    Water bypass pipe-to-engine block bolt
     
    Air cleaner and hose assembly
     
    negative battery cable
     

  6.  


    Click image to see an enlarged view

    Fig. Exploded view of the exhaust system-1.6L (ZM) engines


2.0L (Fs) Engine


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.  

2.0L (Lf) Engine


Click image to see an enlarged view

Fig. Exploded view of the exhaust manifold assembly and related components-Non California emissions models-Mazda 3 models



Click image to see an enlarged view

Fig. Exploded view of the exhaust manifold assembly and related components-California emissions models-Mazda 3 models

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the plug hole plate.
  4.  
  5. Remove the battery cover and duct.
  6.  
  7. Remove the under cover.
  8.  
  9. Remove the rear and front tunnel members.
  10.  
  11. If necessary, remove the main silencer as follows:
    1. Disconnect the ABS sensor wiring harness connector.
    2.  
    3. Disengage the brake pipe mount from the bracket and remove the lower shock absorber bolts.
    4.  
    5. Loosen the rear crossmember bolts and lower the crossmember approximately 3 inches (70mm) and remove the main silencer.
    6.  

  12.  
  13. Unplug both Oxygen Sensor (O 2 S) connectors.
  14.  
  15. Remove the exhaust manifold bracket, heat shield and clip.
  16.  
  17. Remove the front wheels.
  18.  
  19. Disconnect the steering shaft from the steering gear and linkage side.
  20.  
  21. Support the engine and remove the No. 1 engine mount.
  22.  
  23. Loosen the exhaust manifold bolts.
  24.  
  25. Remove the front stabilizer and stabilizer control link bolts.
  26.  
  27. Loosen the front crossmember bolts and lower the crossmember approximately 4 inches (100mm).
  28.  
  29. Support the flexible pipe with a support wrap or splint as illustrated.

    Click image to see an enlarged view

    Fig. Support the flexible pipe with a support wrap or splint-Mazda 3 models

  30.  
  31. Remove the exhaust manifold and gasket.
  32.  

To install:

  1. Installation a new exhaust manifold gasket and the manifold . Tighten the manifold retainers in the sequence illustrated to 32-47 ft. lbs. (43-64 Nm).

    Click image to see an enlarged view

    Fig. Tighten the manifold retainers in this sequence-Mazda 3 models

  2.  
  3. Install the remaining components in the reverse order of removal, using the exploded view of the exhaust system for component location and torque specifications.
  4.  

2.0L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust manifold insulator
     
    Oxygen (O 2 S) sensor electrical connector
     
    Oxygen (O 2 S) sensor, 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 17 ft. lbs. (23 Nm)
     
    Exhaust pipe flange using a new gasket. Torque the nuts to 34 ft. lbs. (46 Nm)
     
    Exhaust Gas Recirculation (EGR) pipe, if equipped
     
    Oxygen (O 2 S) sensor, if necessary
     
    Oxygen (O 2 S) sensor electrical connector
     
    Exhaust manifold insulator
     
    Negative battery cable
     

  4.  

2.3L (Kj) Engine
  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
     
    Front and rear exhaust pipe nuts and lower the exhaust system
     



    Exhaust Gas Recirculation (EGR) pipe, if removing the rear (right side) manifold
     
    Charge air cooler and coolant/condenser fans, If removing the front (left side) manifold
     
    Front and rear Oxygen Sensor (O 2 S) connectors
     
    3 heat shield bolts and the heat shield
     
    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 bolts to 14-18 ft. lbs. (18-24 Nm).
     
    Heat shield. Torque the bolts to 70-95 inch lbs. (8-11 Nm).
     
    O 2 S connectors
     
    Coolant/condenser fans and the charge air cooler, if installing the front (left side) manifold. Torque the bolts to 14-18 ft. lbs. (19-25 Nm).
     
    EGR pipe, if installing the rear (right side) manifold
     
    Exhaust pipes using new gaskets. Torque the nuts to 28-38 ft. lbs. (38-51 Nm).
     
    Negative battery cable
     

  4.  

2.3L (L3) Engine


Click image to see an enlarged view

Fig. Exploded view of the exhaust manifold assembly mounting and related components-Mazda 6 with the 2.3L (L3) engine

  1. Refer to the exploded view illustration for component location and torque specifications.
  2.  
  3. Before servicing the vehicle, refer to the Precautions section.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the main silencer and pre-silencer.
  8.  
  9. Remove the Three Way Converter (TWC).
  10.  
  11. Remove the manifold upper insulator.
  12.  
  13. Remove the bracket.
  14.  
  15. Remove the exhaust manifold and gasket. Discard the gasket.
  16.  

To install:

  1. Clean the manifold mating surfaces.
  2.  
  3. Install a new gasket and the manifold.
  4.  
  5. Tighten the manifold retainers in the sequence illustrated to 32-47 ft. lbs. (43-64 Nm).

    Click image to see an enlarged view

    Fig. Exhaust manifold torque sequence-Mazda 6 with the 2.3L (L3) engine

  6.  
  7. Install the bracket as follows :
    1. Install the bracket and hand tighten the manifold side bolts.
    2.  
    3. Measure the gap between the manifold and bracket it should be 0.08-0.18 inch (2-4mm).
    4.  
    5. Tighten the cylinder block side bolt to 27-38 ft. lbs. (37-52 Nm).
    6.  
    7. Tighten the manifold side bolts to 29-40 ft. lbs. (40-55 Nm).
    8.  

  8.  
  9. Tighten the manifold upper insulator bolts in the sequence illustrated to 70-95 inch lbs. (7-10 Nm).
  10.  
  11. Install the remaining components on the reverse order of removal, referring to the illustration for torque specifications.

    Click image to see an enlarged view

    Fig. Measure the gap between the manifold and bracket-Mazda 6 with the 2.3L (L3) engine



    Click image to see an enlarged view

    Fig. Tighten the manifold upper insulator bolts in this sequence-Mazda 6 with the 2.3L (L3) engine

  12.  

2.3L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this 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
     
    Front and rear exhaust pipe nuts and lower the exhaust system
     



    Exhaust Gas Recirculation (EGR) pipe, if removing the rear (right side) manifold
     
    Charge air cooler and coolant/condenser fans, If removing the front (left side) manifold
     
    Front and rear Oxygen (O 2 S) sensor connectors
     
    3 heat shield bolts and the heat shield
     
    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 bolts to 12-16 ft. lbs. (16-22 Nm)
     
    Heat shield. Torque the bolts to 70-95 inch lbs. (8-11 Nm)
     
    O 2 S connectors
     
    Coolant/condenser fans and the charge air cooler, if installing the front (left side) manifold. Torque the bolts to 14-18 ft. lbs. (19-25 Nm)
     
    EGR pipe, if installing the rear (right side) manifold
     
    Exhaust pipes using new gaskets. Torque the nuts to 28-38 ft. lbs. (38-51 Nm).
     
    Negative battery cable
     

  4.  

2.5L (Kl) Engine
  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 Sensor (O 2 S) 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
     
    Nuts and 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 12-16 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.  

2.5L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this 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

    Click image to see an enlarged view

    Fig. Exploded view of the exhaust manifolds-2.5L engine, 2.3L engine is similar

     
    Front and rear exhaust pipe nuts and lower the exhaust system
     



    Exhaust Gas Recirculation (EGR) pipe, if removing the rear (right side) manifold
     
    3 heat shield bolts and the 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 to 15-20 ft. lbs. (20-28 Nm) and the bolts to 12-16 ft. lbs. (16-22 Nm)
     
    Heat shield. Torque the bolts to 89 inch lbs. (10 Nm)
     
    EGR pipe, 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.  

  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.  

3.0L (Aj) Engine


Click image to see an enlarged view

Fig. Exploded view of the exhaust manifold assembly mounting and related components-Mazda 6 with the 3.0L (AJ) engine

  1. Refer to the exploded view illustration for component location and torque specifications.
  2.  
  3. Before servicing the vehicle, refer to the Precautions section.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the main silencer and pre-silencer.
  8.  
  9. Remove the Three Way Converter (TWC) from the left or right side depending on which manifold is being replaced.
  10.  
  11. Remove the stud bolt.
  12.  
  13. Remove the front pipe.
  14.  
  15. Unplug both Heated Oxygen Sensor (HO 2 S) connectors.
  16.  
  17. Remove the Exhaust Gas Recirculation (EGR) pipe.
  18.  
  19. Remove the exhaust manifold and gasket, from the left or right side depending on which manifold is being replaced. If removing the right hand side manifold, remove the alternator bracket first.
  20.  
  21. Discard the manifold gasket.
  22.  

To install:

  1. Clean the manifold mating surfaces.
  2.  
  3. Install a new gasket and the manifold.
  4.  
  5. Tighten the manifold retainers in the sequence illustrated to 14-19 ft. lbs. (19-26 Nm).

    Click image to see an enlarged view

    Fig. Left side exhaust manifold torque sequence-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Right side exhaust manifold torque sequence-Mazda 6 with the 3.0L (AJ) engine

  6.  
  7. Install the remaining components on the reverse order of removal, referring to the illustration for torque specifications.
  8.  

Mazdaspeed6
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the main silencer.
  6.  
  7. Remove the Three Way Converter (TWC).
  8.  
  9. Remove the rear oxygen sensor.
  10.  
  11. Remove the front pipe.
  12.  
  13. Remove the charge air cooler and the charge air cooler bracket.
  14.  
  15. Remove the cowl grille.
  16.  
  17. Remove the insulators
  18.  
  19. Remove the manifold upper and lower insulator.
  20.  
  21. Remove the front oxygen sensor.
  22.  
  23. Set the alternator out of the way.
  24.  
  25. Disconnect the vacuum hose on the master cylinder side.
  26.  
  27. Remove the warm up three way converter.
  28.  
  29. Remove the exhaust manifold and gasket. Discard the gasket.
  30.  

To install:

  1. Installation is the reverse of removal, note the following:
    1. Clean the manifold mating surfaces.
    2.  
    3. Install a new gasket and the manifold.
    4.  
    5. Tighten the manifold retainers in the sequence illustrated to 32-47 ft. lbs. (43-64 Nm).

      Click image to see an enlarged view

      Fig. Exhaust manifold torque sequence-Mazdaspeed6 with the 2.3L (L3) engine

    6.  
    7. Tighten the installation nuts between the catalytic converter and middle pipe. Tighten to 32-47 ft. lbs. (43-64 Nm).
    8.  
    9. Tighten the installation nuts between main silencer and middle pipe in the order of left side, then right side. Tighten to 29-37 ft. lbs. (38-51 Nm).
    10.  

  2.  

 
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