Mazda Car 2005-06

Exhaust Manifold

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the front and oxygen sensor connectors.
  4.  
  5. Move the water pipe and heater hose slightly out of the way.
  6.  
  7. Disconnect the ventilation hose from the cylinder head
  8.  
  9. Remove the upper exhaust manifold insulator as follows:
    1. Remove the battery and battery tray.
    2.  
    3. Remove the drive belt.
    4.  
    5. Remove the under cover.
    6.  
    7. Remove the suspension tower bar (joint) and (right side).
    8.  
    9. Remove the alternator.
    10.  
    11. Remove the upper insulator.
    12.  

  10.  
  11. Remove the lower exhaust manifold insulator.
  12.  
  13. Remove the exhaust manifold bracket.
  14.  
  15. Remove the exhaust manifold.
  16.  

To install:

  1. Installation is the reverse of removal, please note the following:
    1. Install the manifold and tighten the retainers to 43-64 Nm (32-47 ft. lbs.)
    2.  
    3. Tighten the exhaust manifold bracket to 38-52 Nm (29-38 ft. lbs.).
    4.  
    5. Tighten the upper and lower insulators to 8-11 Nm (70-95 in. lbs.).
    6.  
    7. If removed, tighten the front and oxygen sensors to 29-39 Nm (22-36 ft. lbs.)
    8.  

  2.  

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-Mazda3 models



Click image to see an enlarged view

Fig. Exploded view of the exhaust manifold assembly and related components-California emissions models-Mazda3 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 2.8 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 3.94 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-Mazda3 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-Mazda3 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.  

2.3L (L3) Engine


Click image to see an enlarged view

Fig. Exploded view of the exhaust manifold assembly mounting and related components-Mazda6 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 presilencer.
  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-Mazda6 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-Mazda6 with the 2.3L (L3) engine



    Click image to see an enlarged view

    Fig. Tighten the manifold upper insulator bolts in this sequence-Mazda6 with the 2.3L (L3) engine

  12.  

3.0L (Aj) Engine


Click image to see an enlarged view

Fig. Exploded view of the exhaust manifold assembly mounting and related components-Mazda6 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 presilencer.
  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-Mazda6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Right side exhaust manifold torque sequence-Mazda6 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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