Removal
Remove the battery cover.
Disconnect the negative cable from the battery.
Remove the bottom cover.
Fig. 2.331. Components of the exhaust system of a vehicle with a Z6 engine: 1 – rear tunnel cross member; 2 – front tunnel crossmember; 3 – main muffler; 4 – rear heated oxygen concentration sensor; 5 – Front heated oxygen concentration sensor; 6 – exhaust gas recirculation pipe (from the exhaust manifold side); 7 – element; 8 – exhaust manifold bracket; 9 – clamp; 10 – Three-way catalytic converter; 11 – exhaust manifold heat shield; 12 – exhaust manifold gasket
Remove the components in the order shown in Figure 2.331.
Removal the exhaust manifold / exhaust manifold heat shield
Caution: Excessive bending of the exhaust pipe may cause damage to it.
Note: When removing the exhaust manifold, move the exhaust manifold heat shield aside slightly, loosen the nuts, and then remove the exhaust manifold together with the shield. Refer to the following procedure.
Remove the front wheels.
Remove the air filter cover and air filter housing.
Remove the exhaust gas recirculation pipe (from the intake manifold side).
Remove the EGR valve assembly.
Disconnect the steering shaft from the steering gear, disconnect the steering rods.
Disconnect the pressure hose and return hose.
Remove engine mount #1.
Loosen the exhaust manifold heat shield bolts.
Move the exhaust manifold heat shield slightly to the side and loosen the exhaust manifold nuts.
Remove the front crossmember and front anti-roll bar mounting bolts.
Loosen the front cross member mounting bolts and lower the front cross member by approximately 100 mm.
Fig. 2.332. Securing a flexible pipe
Tie the flexible pipe or fix it as shown in Figure 2.332.
Remove the exhaust manifold together with the insulator, lowering it to the bottom of the car.
Installation
Fig. 2.333. Tightening order of exhaust manifold mounting bolts
Tighten the exhaust manifold mounting nuts in the order shown in Figure 2.333.
Fig. 2.334. Tightening order of bolts and nuts of the exhaust gas recirculation pipe
Tighten the EGR pipe bolts and nuts in the order shown in Figure 2.334.
Install the remaining components in the reverse order of removal