Catalytic converter (M4R engine)
Place the car on a lift.
Disconnect the battery. Disconnect the connector from the holder (1) upstream oxygen sensor of the catalytic converter.
Disconnect the upstream oxygen sensor connector.
Remove the catalytic converter downstream oxygen sensor and shield.
Cut the exhaust pipe. Place a jack under the catalytic converter.
Remove:
- bolts (2) fixing the exhaust pipe flange;
- catalytic converter; exhaust pipe flange ring;
- upstream oxygen sensor with catalytic converter.
Clean and degrease the bearing surfaces of the catalytic converter.
Replace the ring between the exhaust manifold and catalytic converter.
Install the parts in reverse order.
Catalytic converter (K4M engine)
Place the car on a lift.
Disconnect the wires from the battery terminals, starting with the negative terminal.
Remove the engine undertray.
Remove the downstream oxygen sensor.
Cut the exhaust pipe.
Loosen nuts (1) securing the exhaust pipe flange and remove the catalytic converter.
Attention. Do not use a used coupling.
When assembled, the coupling bolt and nut must be oriented so that they do not come into contact with the bottom of the body.
A damaged heat shield must be replaced.
Install the downstream oxygen sensor.
Torque tighten (45 Nm) oxygen sensor with tool (Mot. 1495-01). Torque tighten if necessary (7 Nm) exhaust pipe flange studs.
Install catalytic converter and clutch
The rest of the equipment is installed in the reverse order of removal.
Attention. Be sure to replace the exhaust manifold flange gasket and any disconnected plastic air intake ducts.
Torque tighten (21 Nm) exhaust pipe flange nuts.
Tighten the coupling, unloading the exhaust pipe to line it up.
Connect the oxygen sensor.
Ensure that all exhaust system heat shields are present and secure.
Install the engine undertray.
Make sure the exhaust pipe is not in contact with the underbody.
Attach the wires to the battery terminals, starting with the positive terminal.
Main silencer
Place the car on a lift.
Cut the exhaust pipe. Install a jack under the muffler. Loosen the main muffler mount bolts (1).
Note. If the suspension pads are damaged, replace them.
Remove the main muffler.
Attention. When installing, position the coupling bolt and clamp nut so that they do not come into contact with the body.
Tighten the coupling, unloading the exhaust pipe to line it up.
Check:
- the presence and reliable fastening of all thermal screens of the exhaust pipeline;
- lack of contact with the bottom of the body.
Start the engine.
Check for leaks and repair if found.
Additional silencer
Place the car on a lift.
Cut the exhaust pipe. Install a jack under the muffler. Remove mounting bolts (1) silent block of the additional muffler.
Disconnect «mass» wire on silent block (2) and remove the additional muffler.
Note. New additional mufflers, which are supplied in the repair kit, must be modified before being installed on the vehicle.
On the workbench, cut off part of the additional muffler (3) using a cutter for the exhaust pipe (diameter 35/50 mm and diameter 50/65 mm). Complete set in hard case (Mot. 1199-01) at the following distance from the inlet:
- JZXX long chassis - no cuts required;
- JZXX standard chassis / KZXX - 69 mm;
- BZXK/DZXX - 129 mm.
Install the parts in reverse order.