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)].)

3. Remove in the order indicated in the table.

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

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

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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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.

Tightening torque

3.4—5.4 N·m {35—55 kgf·cm, 31—47 in·lbf}

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
13	Heat insulter
14	Exhaust manifold insulator
15	Exhaust manifold
16	Exhaust manifold gasket