Mazda RX-8 2004-06

Exhaust Manifold

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Removal & Installation



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

    negative battery cable
     
    Front and rear tunnel crossmembers
     
    Main silencer
     
    Middle exhaust pipe
     
    Protector
     
    Rear oxygen sensor
     
    Catalytic converter
     
    Bracket
     
    Front oxygen sensor
     
    Air Injection reactor (AIR pipe)
     

  4.  
  5. Use a suitable overhead engine lift and support the engine.
  6.  
  7. Remove the right side engine mounting rubber and bracket.
  8.  
  9. Remove the exhaust manifold.
  10.  


    Click image to see an enlarged view

    Fig. Exploded view of the exhaust system-RX-8



    Click image to see an enlarged view

    Fig. Exhaust manifold gasket identification-RX-8



    Click image to see an enlarged view

    Fig. Removing and installing the engine mount bracket-RX-8


To install:

  1. Clean all gasket mating surfaces.
  2.  


NOTE
Use new self-locking nuts. The exhaust manifold gasket has crimps attached to it. Ensure that all the crimps are in place when installing the gasket, or the gasket will leak.

  1. Install or connect the following:

    Exhaust manifold. Torque the nuts to 31-44 ft. lbs. (43-61 Nm).
     
    Right side engine mounting bracket. Torque the bolts as shown.
     
    Air Injection reactor (AIR pipe)
     
    Bracket
     
    Catalytic converter
     
    Rear oxygen sensor
     
    Protector
     
    Middle exhaust pipe
     
    Main silencer
     
    Front and rear tunnel crossmembers and torque the bolts to 14-19 ft. lbs. (19-26 Nm)
     
    negative battery cable
     

  2.  
  3. On models with dynamic suspension, perform the steering angle sensor initialization procedure.
  4.  

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

    Negative battery cable
     
    Front and rear tunnel crossmembers
     
    Main silencer
     
    Middle exhaust pipe
     
    Protector
     
    Rear oxygen sensor
     
    Catalytic converter
     
    Bracket
     
    Front oxygen sensor
     
    Air Injection reactor (AIR pipe)
     

  4.  
  5. Use a suitable overhead engine lift and support the engine.
  6.  
  7. Remove the right side engine mounting rubber and bracket.
  8.  
  9. Remove the exhaust manifold.

    Click image to see an enlarged view

    Fig. Exploded view of the exhaust system-RX-8



    Click image to see an enlarged view

    Fig. Exhaust manifold gasket identification-RX-8



    Click image to see an enlarged view

    Fig. Removing and installing the engine mount bracket-RX-8

  10.  

To install:

  1. Clean all gasket mating surfaces.
    NOTE
    Use new self-locking nuts. The exhaust manifold gasket has crimps attached to it. Ensure that all the crimps are in place when installing the gasket, or the gasket will leak.

  2.  
  3. Install or connect the following:

    Exhaust manifold. Torque the nuts to 31-44 ft. lbs. (43-61 Nm).
     
    Right side engine mounting bracket. Torque the bolts as shown.
     
    Air Injection reactor (AIR pipe)
     
    Bracket
     
    Catalytic converter
     
    Rear oxygen sensor
     
    Protector
     
    Middle exhaust pipe
     
    Main silencer
     
    Front and rear tunnel crossmembers and torque the bolts to 14-19 ft. lbs. (19-26 Nm)
     
    Negative battery cable
     

  4.  
  5. On models with dynamic suspension, perform the steering angle sensor initialization procedure.
  6.  

 
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