Exhaust Manifold

REMOVAL AND INSTALLATION

1993-94 323 1.6L (B6E)

1. Disconnect the negative battery cable.
2. Remove the retaining bolts and remove the exhaust manifold insulator.
3. Disconnect the oxygen sensor electrical connector. Remove the oxygen sensor, if necessary, if it is installed in the manifold.
4. Disconnect the EGR pipe, if equipped.
5. Raise and safely support the vehicle. Remove the nuts from the exhaust pipe flange and disconnect the exhaust pipe from the manifold or turbocharger, if equipped.
6. Lower the vehicle.
7. Remove the mounting nuts/bolts and remove the exhaust manifold.
8. Installation is the reverse of the removal procedure. Make sure all gasket mating surfaces are clean prior to assembly.
9. Use new gaskets and tighten the exhaust manifold-to-cylinder head nuts/bolts to specifications.
10. Use a new gasket and tighten the exhaust pipe flange-to-exhaust manifold nuts to 34 ft. lbs. (46 Nm).

1993-97 Protege 1.5L (Z5D) and 1.8L (BPE,BPD) Engines

1. Disconnect the negative battery cable.
2. Remove the air cleaner, and disconnect the air hose.
3. Remove the water bypass pipe bolt.
4. Remove the exhaust manifold heat shield bolts and the heat shield.
5. Disconnect the oxygen sensor electrical connector.
6. Raise and safely support the vehicle.
7. Remove and discard the exhaust pipe-to-exhaust manifold nuts. Suspend the exhaust system with wire.
8. Disconnect the EGR pipe from the exhaust manifold and lower the vehicle.
9. Remove the nuts and bolts and remove the exhaust manifold. Discard the nuts.

   To install:

10. Clean all gasket mating surfaces.
11. Position a new exhaust manifold gasket over the studs and install the exhaust manifold. Tighten the mounting nuts and bolts to 14-16 ft. lbs. (19-22 Nm) on the 1.5L, and for the 1.8L to 29-34 ft. lbs. (39-47 Nm).
12. Raise and safely support the vehicle.
13. Connect the exhaust pipe to the manifold. Install new nuts and tighten to 38 ft. lbs. (52 Nm). Connect the oxygen sensor connector.
14. Connect the EGR pipe to the back of the exhaust manifold and tighten to 34 ft. lbs. (47 Nm). Lower the vehicle.
15. Install the heat shield and tighten the bolts to 88 inch lbs. (10 Nm).
16. Install the water bypass pipe bolt, and tighten to 48-65 ft. lbs. (64-89 Nm).
17. Connect the air hose, and install the air cleaner.
18. Connect the negative battery cable.

1993-95 MX3 1.8L (K8) and 1993-97 626 and MX6 2.5L (KL) Engines

1. Disconnect the negative battery cable. Raise and safely support the vehicle.
2. Disconnect the oxygen sensor connectors.
3. Remove the nuts from the front and rear exhaust pipes and lower the exhaust system. Both pipes must be disconnected, even if only one manifold is to be removed.
4. If removing the rear (right side) manifold, disconnect the EGR pipe.
5. Remove the 3 heatshield bolts and remove the heat shield.
6. Remove the 2 nuts and 5 bolts and remove the exhaust manifold.

   To install:

7. Clean all gasket mating surfaces.
8. Install the exhaust manifold, using a new gasket, and tighten the nuts to 15-20 ft. lbs. (20-28 Nm), and the bolts to 12-16 ft. lbs. (16-22 Nm).
9. Install the heat shield and tighten the bolts to 88 inch lbs. (10 Nm).
10. If installing the rear (right side) manifold, connect the EGR pipe.
11. Connect the exhaust pipes to the manifolds, using new gaskets and nuts, and tighten the nuts to 38 ft. lbs. (51 Nm).
12. Connect the oxygen sensor connectors and lower the vehicle.
13. Connect the negative battery cable.

1993-95 MX3 1.6L (B6-ZE) Engine

1. Disconnect the negative battery cable.
2. Remove the 4 exhaust manifold heat shield bolts and the heat shield.
3. Disconnect the oxygen sensor electrical connector.
4. Raise and safely support the vehicle. Remove the nuts from the exhaust pipe flange and disconnect the exhaust pipe from the manifold. Suspend the exhaust system with wire.
5. Disconnect the EGR pipe.
6. Lower the vehicle.
7. Remove the mounting nuts/bolts and remove the exhaust manifold.

   To install:

8. Clean all gasket mating surfaces.
9. Position a new exhaust manifold gasket over the studs and install the exhaust manifold. Tighten the 8 mounting bolts/nuts to 29-33 ft. lbs. (39-46 Nm).
10. Raise and safely support the vehicle.
11. Connect the exhaust pipe to the manifold. Install new nuts and tighten to 38 ft. lbs. (52 Nm). Connect the oxygen sensor connector.
12. Install the two inlet pipe bracket bolts.
13. Connect the EGR pipe to the back of the exhaust manifold. Lower the vehicle.
14. Install the heat shield and tighten the bolts to 70-95 inch lbs. (8-11 Nm). Connect the negative battery cable.

1993-97 626 and MX6 2.0L (FS) Engines

1. Disconnect the negative battery cable.
2. Raise and safely support the vehicle.
3. Disconnect the front exhaust pipe from the exhaust manifold.
4. Lower the vehicle.
5. Remove the power steering oil pump and the mounting bracket.
6. Remove the exhaust manifold heat shield bolts and the heat shield.
7. Disconnect the EGR pipe from the manifold.
8. Disconnect the oxygen sensor electrical connector from the manifold.
9. Remove the manifold mounting nuts and bolts, remove the manifold.

   To install:

10. Clean all gasket mating surfaces.
11. Position a NEW exhaust manifold gasket over the studs and install the exhaust manifold. Tighten the mounting bolts to 12-16 ft. lbs. (16-22 Nm).
12. Install NEW manifold mount nuts and tighten to 15-20 ft. lbs. (20-28 Nm). Raise and safely support the vehicle.
13. Connect the oxygen sensor electrical connector and the EGR pipe to the manifold.
14. Install the heat shield and tighten the bolts to 70-95.4 in. lbs. (7.9-10.7 Nm).
15. Install the power steering oil pump bracket and the oil pump.
16. Raise and safely support the vehicle.
17. Connect the front exhaust pipe to the manifold, use a NEW gasket. Install NEW nuts and tighten to 28-38 ft. lbs. (38-51 Nm).
18. Connect the negative battery cable.

1993-95 929 3.0L (JE-ZE) Engines

1. Disconnect the negative battery cable.
2. Remove the retaining bolts, and remove the exhaust manifold insulator.
3. Disconnect the oxygen sensor electrical connector.
4. Disconnect the EGR pipe.
5. Raise and safely support the vehicle. Remove and discard the nuts from the exhaust pipe flange, and disconnect the exhaust pipe from the manifold.
6. Lower the vehicle.
7. Remove and discard the mounting nuts, and remove the exhaust manifold.

   To install:

8. Make sure all gasket mating surfaces are clean prior to assembly.
9. Using a new gasket, install the exhaust manifold to the cylinder head. Tighten the new mounting nuts to14-18 ft. lbs. (19-25 Nm).
10. Raise and safely support the vehicle.
11. Using a new gasket, install the exhaust pipe flange to the exhaust manifold nuts. Tighten the new nuts to 28-38 ft. lbs. (38-51 Nm). Lower the vehicle.
12. Connect the EGR pipe and the oxygen sensor.
13. Install the exhaust manifold insulators, and tighten the bolts to 14-18 ft. lbs. (19-25 Nm).
14. Connect the negative battery cable.

1995-97 Millenia

1. Disconnect the negative battery cable.
2. Raise and safely support the vehicle.
3. Remove the nuts from the front and rear exhaust pipes and lower the exhaust system. Both pipes must be disconnected, even if only one manifold is to be removed.
4. If removing the rear (right side) manifold, disconnect the EGR pipe.
5. If removing the front (left side) manifold, remove the charge air cooler and the coolant/condenser fans.
6. Disconnect the front and rear oxygen sensor connectors.
7. Remove the three heat shield bolts and remove the heat shield.
8. Remove the 2 nuts and 5 bolts and remove the exhaust manifold.

   To install:

9. Clean all gasket mating surfaces.
10. Install the exhaust manifold, using a new gasket, and tighten the nuts and bolts to 12-16 ft. lbs. (16-22 Nm).

    Fig. 1: Exhaust manifold mounting bolt torque sequence -- 1995-97 Millenia 2.3L (KJS) engines

11. Install the heat shield and tighten the bolts to 70-95 inch lbs. (8-11 Nm).
12. Connect the oxygen sensor connectors.
13. If installing the front (left side) manifold, install the the coolant/condenser fans and the charge air cooler. Tighten the charge air cooler mounting bolts to 14-18 ft. lbs. (19-25 Nm)
14. If installing the rear (right side) manifold, connect the EGR pipe.
15. Connect the exhaust pipes to the manifolds, using new gaskets and nuts, and tighten the nuts to 28-38 ft. lbs. (38-51 Nm).
16. Lower the vehicle.
17. Connect the negative battery cable.

Miata 1.6L (B6-ZE) and 1.8L (BPD) Engines

1. Disconnect the negative battery cable.
2. Remove the retaining bolt, and remove the exhaust manifold insulator.
3. Disconnect the oxygen sensor electrical connector. Remove the oxygen sensor.
4. Raise and safely support the vehicle. Remove the nuts from the exhaust pipe flange and disconnect the exhaust pipe from the manifold.
5. Lower the vehicle.
6. Remove the mounting nuts/bolts and remove the exhaust manifold.

   To install:

7. Make sure all gasket mating surfaces are clean prior to assembly.
8. Use new gaskets and tighten the exhaust manifold nuts/bolts to the cylinder head. Torque to 29-33 ft. lbs. (39-46 Nm).
9. Raise and safely support the vehicle.
10. Use a new gasket and tighten the exhaust pipe flange, to the exhaust manifold nuts, to 34 ft. lbs. (46 Nm).
11. Lower the vehicle. Install the oxygen sensor, and connect the electrical connector.
12. Install the exhaust manifold insulator, and tighten the mounting bolt to 70-95 inch lbs. (8-11 Nm).
13. Connect the negative battery cable.

1993-95 RX7 1.3L (13B)

1. Disconnect the negative battery cable.
2. Remove the intake manifold assembly.
3. Remove the exhaust shields.
4. Disconnect the oxygen sensor connector.
5. Disconnect the exhaust pipe from the turbocharger.
6. Remove the turbocharger and wastegate assembly and cover the air, water and oil openings to keep them clean.
7. Remove the nuts to remove the exhaust manifold from the engine. Cover the exhaust ports to keep dirt out of the engine.

   To install:

8. Clean all gasket mating surfaces.
9. Using a new gasket, install the exhaust manifold to the engine.
10. Install new nuts, and tighten to 57 ft. lbs. (78 Nm).
11. Install the turbocharger and wastegate assembly.
12. Connect the exhaust pipe to the turbocharger. Tighten the nuts to 28-38 ft. lbs. (38-51 Nm).
13. Connect the oxygen sensor connector, and install the exhaust shields.
14. Install the intake manifold assembly.
15. Connect the negative battery cable.
16. Start the engine and bring to normal operating temperature. Check for leaks.