EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6]

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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

•  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 VALUES RESET [MZ-CD 1.6].) (See DIESEL PARTICULATE FILTER STATIC REGENERATION [MZ-CD 1.6].)

•  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].)

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

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

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

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

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.

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].)
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

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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1	Insulator (rear No.1) (See Insulator (rear No.1, No.2) removal note.)
2	Insulator (rear No.2) (See Insulator (rear No.1, No.2) removal note.)
3	Insulator (middle No.1)
4	Insulator (middle No.2)
5	Insulator (front)

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.

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].)

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