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

EURO4 emission level

• Perform the “DIESEL PARTICULATE FILTER LEARNED VALUE RESET” when replacing the diesel particulate filter (catalytic converter). (See DIESEL PARTICULATE FILTER LEARNED VALUE RESET [MZ-CD 1.6 (Y6) (EURO4 emission level)].)

EURO5 emission level

• If the catalytic converter is replaced, complete the “DIESEL PARTICULATE FILTER LEARNED VALUE RESET” and “DIESEL PARTICULATE FILTER STATIC REGENERATION”. (See DIESEL PARTICULATE FILTER LEARNED VALUE RESET [MZ-CD 1.6 (Y6) (EURO5 emission level)].) (See DIESEL PARTICULATE FILTER STATIC REGENERATION [MZ-CD 1.6 (Y6) (EURO5 emission level)].)

• If the exhaust gas temperature sensor is replaced, complete the “EXHAUST GAS TEMPERATURE VALUE RESET”. (See EXHAUST GAS TEMPERATURE VALUE RESET [MZ-CD 1.6 (Y6) (EURO5 emission level)].)

• If the turbocharger is replaced, complete the “TURBOCHARGER LEARNED VALUES RESET”. (See TURBOCHARGER LEARNED VALUES RESET [MZ-CD 1.6 (Y6) (EURO5 emission level)].)

1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION[MZ-CD 1.6 (Y6)].)

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

3. Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6) (EURO4 emission level)].)

4. Remove the aerodynamic under cover No.2. (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.)

5. Remove in the order indicated in the table.

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

7. Install in the reverse order of removal.

EURO4 emission level

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1

Tunnel member

2

Main silencer

(See Main Silencer Removal Note.)

3

Hanger bracket No.1

4

Flexible pipe

(See Flexible Pipe Removal Note.)

5

Exhaust gas temperature sensor

6

Catalytic converter front insulator

(See Catalytic Converter Front Insulator Removal Note.)

7

Hanger bracket No.2

8

Protector bracket

9

Catalytic converter rear insulator

(See Catalytic Converter Rear Insulator Removal Note.)

10

Exhaust gas pressure hose

11

Clamp

(See Clamp Installation Note.)

12

Catalytic converter

13

Exhaust manifold insulator

14

Turbocharger

(See Turbocharger Replacement Note.)

(See Turbocharger Removal Note.)

15

Exhaust manifold

16

Exhaust manifold gasket

EURO5 emission level (Step1)

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1

Tunnel member

2

Main silencer

(See Main Silencer Removal Note.)

3

Front pipe

4

A/F sensor

(See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6) (EURO5 emission level)].)

5

Catalytic converter upper insulator

6

Catalytic converter front insulator

(See Catalytic Converter Front Insulator Removal Note.)

7

Protector bracket

8

Catalytic converter rear insulator

(See Catalytic Converter Rear Insulator Removal Note.)

9

Exhaust gas pressure hose

10

Clamp

11

Catalytic converter

EURO5 emission level (Step2)

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1

Exhaust manifold insulator No.1

2

Oil inlet pipe

3

Oil outlet pipe

4

Turbocharger

5

Exhaust manifold insulator No.2

6

Exhaust manifold

Exhaust System Insulator Removal/Installation Note

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

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Insulator (rear No.1, No.2) removal note

Note

• The insulator (rear No.1, No.2) is installed using rivets.

• When reinstalling the rivet, install the same rivet or M5 bolt and nut.

1. Push out the mandrel using a hammer and punch (2—2.8 mm {0.08—0.11 in} diameter).

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2. Remove the flange using a drill (5 mm {0.20 in} drill bit).

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Main Silencer Removal Note

1. Remove the following parts:

(1) Rear auto leveling sensor (Vehicles with AFS) (See AUTO LEVELING SENSOR REMOVAL/INSTALLATION.)

(2) Rear stabilizer (See REAR STABILIZER REMOVAL/INSTALLATION.)

(3) Rear coil spring (See REAR COIL SPRING REMOVAL/INSTALLATION.)

(4) Rear lower arm (See REAR LOWER ARM REMOVAL/INSTALLATION.)

(5) Rear crossmember (See REAR CROSSMEMBER REMOVAL/INSTALLATION.)

2. Remove the main silencer.

Flexible Pipe Removal Note

Caution

• Over bending of the 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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2. Remove the flexible pipe.

Catalytic Converter Front Insulator Removal Note

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

2. Remove the catalytic converter front insulator.

Catalytic Converter Rear Insulator Removal Note

1. Remove the catalytic converter and catalytic converter rear insulator as a single unit.

2. Remove the catalytic converter rear insulator

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.

Turbocharger Removal Note

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

2. Remove the turbocharger outlet pipe and charge air cooler inlet hose as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

3. Disconnect the variable boost control valve actuator connector.

4. Disconnect the vacuum hose.

5. Remove the turbocharger and oil inlet pipe and oil outlet pipe as a single unit.

6. Remove in the order indicated in the table.

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1

Oil inlet pipe

2

Oil outlet pipe

3

Turbocharger

Clamp Installation Note

1. Install the clamp as shown in the figure.

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1	Tunnel member
2	Main silencer (See Main Silencer Removal Note.)
3	Hanger bracket No.1
4	Flexible pipe (See Flexible Pipe Removal Note.)
5	Exhaust gas temperature sensor
6	Catalytic converter front insulator (See Catalytic Converter Front Insulator Removal Note.)
7	Hanger bracket No.2
8	Protector bracket
9	Catalytic converter rear insulator (See Catalytic Converter Rear Insulator Removal Note.)
10	Exhaust gas pressure hose
11	Clamp (See Clamp Installation Note.)
12	Catalytic converter
13	Exhaust manifold insulator
14	Turbocharger (See Turbocharger Replacement Note.) (See Turbocharger Removal Note.)
15	Exhaust manifold
16	Exhaust manifold gasket

1	Tunnel member
2	Main silencer (See Main Silencer Removal Note.)
3	Front pipe
4	A/F sensor (See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6) (EURO5 emission level)].)
5	Catalytic converter upper insulator
6	Catalytic converter front insulator (See Catalytic Converter Front Insulator Removal Note.)
7	Protector bracket
8	Catalytic converter rear insulator (See Catalytic Converter Rear Insulator Removal Note.)
9	Exhaust gas pressure hose
10	Clamp
11	Catalytic converter

1	Exhaust manifold insulator No.1
2	Oil inlet pipe
3	Oil outlet pipe
4	Turbocharger
5	Exhaust manifold insulator No.2
6	Exhaust manifold