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). (High power-Euro 4) (See DIESEL PARTICULATE FILTER LEARNED VALUE RESET [MZ-CD 1.6 (Y6)].)

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

2.  Disconnect the negative battery cable.

3.  Remove the engine cover.

4.  Remove the under cover.

5.  Remove the air hose between the turbocharger and air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

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

7.  Remove in the order indicated in the table.

8.  Install in the reverse order of removal.

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1
Front tunnel member
2
Rear tunnel member
3
Main silencer
4
Exhaust manifold flexible pipe
(See Exhaust Manifold Flexible Pipe Removal Note.)
5
Catalyst exhaust gas temperature sensor (High power-Euro 4)
6
Catalytic converter bracket
7
Catalytic converter insulator
(See Catalytic Converter Insulator Installation Note.)
8
Clamp
(See Catalytic Converter and Clamp Installation Note.)
9
Catalytic converter
(See Catalytic Converter and Clamp Installation Note.)
10
Oil pipe
11
Exhaust manifold insulator
12
Turbocharger
(See Turbocharger Replacement Note.)
(See Turbocharger Installation Note.)
13
Exhaust manifold
(See Exhaust Manifold Installation Note.)


Exhaust Manifold Flexible Pipe Removal Note

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

1.  Loosen the exhaust manifold insulator bolts.

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

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3.  Detach the exhaust flexible pipe from the catalytic converter.

4.  Discard the gasket and nuts.


Exhaust Manifold Installation Note

1.  Tighten the exhaust manifold installation nuts in the order 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 pipe and the oil pipe installation bolts.

2.  Verify that there is no blockage caused by particles in the oil pipe and on the oil 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 Installation Note

Note
•  If the catalytic converter has not been removed, be sure to install the turbocharger by following the procedures below. (Only when turbocharger is removed)

1.  Set the new clamp and turbocharger in the engine.

2.  Temporarily tighten the new turbocharger fixing nuts.

Upper nut

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Lower nut

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3.  Temporarily tighten the clamp nut.

Tightening torque
4 N·m {40.8 kgf·cm, 35.4 in·lbf}

4.  Temporarily tighten the turbocharger support bracket bolt and nut.

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5.  Tighten the turbocharger fixing nuts.

Tightening torque
25 N·m {2.55 kgf·m, 18.4 ft·lbf}

6.  Tighten the turbocharger support bracket bolt.

Tightening torque
25 N·m {2.55 kgf·m, 18.4 ft·lbf}

7.  Tighten the turbocharger support bracket nut.

Tightening torque
25 N·m {2.55 kgf·m, 18.4 ft·lbf}

8.  Loosen the clamp nut. When loosening the clamp nut, do not loosen the clamp nut excessively, and try to leave 10 mm {0.39 in} or less of thread.

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9.  Loosen the catalytic converter fixing bolts and nut in the order shown in the figure.

Standard power-Euro 4

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High power-Euro 4

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10.  Tighten the clamp nut.

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

11.  Tighten the catalytic converter fixing bolts and nut in the order shown in the figure.

Standard power-Euro 4

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High power-Euro 4

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Catalytic Converter and Clamp Installation Note


Standard power-Euro 4

1.  Temporarily tighten catalytic converter fixing bolts A by hand until bracket A is attached.

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

3.  Install the catalytic converter by passing the hanger on the pipe of the catalytic converter through the bracket stud under the engine and temporarily tighten with the catalytic converter fixing bolts C.

4.  Tighten the clamp nut B 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}

5.  Tighten the catalytic converter fixing nut D.

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

6.  Tighten the catalytic converter fixing bolts C.

Tightening torque
20—27 N·m {2.1—2.7 kgf·m, 14.8—19.9 ft·lbf}

7.  Tighten the catalytic converter fixing bolts A.

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


High power-Euro 4

1.  Align to the bolt hole position as shown in the figure, and install the rear side of catalytic converter insulator to the catalytic converter, then tighten the bolts.

Tightening torque
8—12 N·m {81.6—122.3 kgf·cm, 70.9—106.2 in·lbf}
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2.  Install bracket A to the engine and temporarily tighten with catalytic converter fixing bolts A.

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3.  Set the new clamp to the pipe of the catalytic converter.

4.  Set bracket C of the catalytic converter on bracket A, which is temporarily installed to the engine, and install the catalytic converter by passing the hanger on the pipe of the catalytic converter through the bracket stud under the engine.

5.  Temporarily tighten the catalytic converter fixing bolts B until bracket A and bracket C are attached.

Tightening torque
5 N·m {51.0 kgf·cm, 44.2 in·lbf} or less

6.  Tighten clamp nut C 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}

7.  Tighten the catalytic converter fixing nut D.

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

8.  Tighten the catalytic converter fixing bolts A.

Tightening torque
20—27 N·m {2.1—2.7 kgf·m, 14.8—19.9 ft·lbf}

9.  Tighten the catalytic converter fixing bolts B.

Tightening torque
20—27 N·m {2.1—2.7 kgf·m, 14.8—19.9 ft·lbf}


Catalytic Converter Insulator Installation Note


Standard power-Euro 4

1.  Install bracket C and temporarily tighten nut E and bolt F.

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2.  Tighten nut E.

Tightening torque
20—26 N·m {2.1—2.6 kgf·m, 14.8—19.1 ft·lbf}

3.  Install the catalytic converter insulator and temporarily tighten bolts G.

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4.  Tighten bolts G.

Tightening torque
8—12 N·m {81.6—122.3 kgf·cm, 70.9—106.2 in·lbf}

5.  Tighten bolts F.

Tightening torque
8—12 N·m {81.6—122.3 kgf·cm, 70.9—106.2 in·lbf}


High power-Euro 4

1.  Temporarily tighten nut E until the stopper of bracket B is completely engaged.

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2.  Tighten nut E.

Tightening torque
20—26 N·m {2.1—2.6 kgf·m, 14.8—19.1 ft·lbf}

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

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4.  Temporarily tighten bolts F.

5.  Tighten bolts F.

Tightening torque
8—12 N·m {81.6—122.3 kgf·cm, 70.9—106.2 in·lbf}