EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)]

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Warning

•  A hot engine and exhaust system can cause severe burns. Turn off the engine and wait until they are cool before removing the exhaust system.

Note

•  Perform the “DIESEL PARTICULATE FILTER LEARNED VALUE RESET” when replacing the diesel particulate filter (catalyst converter). (See DIESEL PARTICULATE FILTER LEARNED VALUE RESET [MZ-CD 1.6 (Y6)].)

1.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

2.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

3.  Remove in the order indicated in the table.

4.  Remove the exhaust system insulator. (See Exhaust System Insulator Removal/Installation Note.)

5.  Install in the reverse order of removal.

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1	Main silencer
2	Tunnel member
3	Middle pipe
4	Front pipe
5	Catalyst exhaust gas temperature sensor No.1
6	Catalyst exhaust gas temperature sensor No.2
7	Upper catalytic converter insulator (See Upper Catalytic Converter Insulator Removal Note.) (See Upper Catalytic Converter Insulator Installation Note.)
8	Clamp (See Catalytic Converter, Hanger Bracket and Clamp Installation Note.)
9	Catalytic converter (See Catalytic Converter Removal Note.) (See Catalytic Converter, Hanger Bracket and Clamp Installation Note.)
10	Hanger bracket (See Catalytic Converter, Hanger Bracket and Clamp Installation Note.)
11	Lower catalytic converter insulator
12	Turbocharger (See Turbocharger Replacement Note.)
13	Heat insulter
14	Exhaust manifold insulator
15	Exhaust manifold
16	Exhaust manifold gasket

Exhaust System Insulator Removal/Installation Note

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Upper Catalytic Converter Insulator Removal Note

1.  Remove the air pipe. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

2.  Set the charge air cooler inlet hose out of the way. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

3.  Disconnect the wiring harness.

4.  Remove the upper catalytic converter insulator.

Catalytic Converter Removal Note

Caution

•  Over bending of the exhaust flexible pipe may cause damage resulting in failure.

1.  Support the flexible pipe with a support wrap or splint as shown in the figure.

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Turbocharger Replacement Note

Note

•  When replacing the turbocharger, perform the following procedure and verify.

Inspection for turbocharger replacement

1.  Remove the oil inlet pipe and the oil inlet pipe installation bolts.

2.  Verify that there is no blockage caused by particles in the oil inlet pipe and on the oil inlet pipe installation bolts.

•  If there is clogging caused by particles, verify the cause and repair the applicable part.

3.  Verify that there are no particles in the lubrication system.

•  If there are any particles, verify the cause and repair or replace if necessary.

4.  Inspect the oil pressure. (See OIL PRESSURE INSPECTION [MZ-CD 1.6 (Y6)].)

•  If not within the specification, verify the cause and repair or replace if necessary.

5.  After determining the reason for the turbocharger damage install a new turbocharger.

Catalytic Converter, Hanger Bracket and Clamp Installation Note

1.  Install the hanger bracket to the engine side.

2.  Set the clamp to the pipe of the catalytic converter.

3.  Install the catalytic converter following procedure.

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(1)  Set the catalytic converter to the turbocharger.

(2)  Temporarily tighten bolt and nut shown in the figure.

(3)  Temporarily tighten the clamp nut.

(4)  Tighten bolt and nut shown in the figure.

Tightening torque

20—28 N·m {2.1—2.8 kgf·m, 15—20 ft·lbf}

(5)  Tighten clamp nut with the clamp stud pointing downwards from the level position.

Tightening torque

20—30 N·m {2.1—3.1 kgf·m, 14.8—22.1 ft·lbf}

Upper Catalytic Converter Insulator Installation Note

1.  Set the upper catalytic converter insulator to the engine side.

2.  Secure the front and rear insulators with the clip as shown in the figure.

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3.  Temporarily tighten upper catalytic converter insulator bolts.

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4.  Tighten upper catalytic converter insulator bolts.