EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2]SM2444791
EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2]

id0115f2800200

Warning
• When the engine and exhaust system are hot, they can cause severe burns or injury. Turn off the engine and wait until they are cool before removing the exhaust system.
Caution
• Perform exhaust gas temperature sensor removal/installation only when inspection or replacement is required, such as when DTCs for the sensor are displayed, because it may cause exhaust gas leaks. If removal or installation/removal is performed, always verify that there is no exhaust gas leak after reinstallation.
Note
• If the diesel particulate filter indicator light is flashing and/or the MIL is illuminated, perform the symptom troubleshooting and verify the DTC of the diesel particulate filter system by using the M-MDS before removing parts. If any DTCs are displayed, perform troubleshooting according to the corresponding DTC inspection. (See DTC TABLE [MZR-CD 2.2].) (See SYMPTOM DIAGNOSTIC INDEX [MZR-CD 2.2].)
• If the diesel particulate filter indicator light is illuminated, inspect the symptom troubleshooting procedure of the diesel particulate filter system before removing parts. (See SYMPTOM DIAGNOSTIC INDEX [MZR-CD 2.2].)
• If the oxidation catalytic converter (built-in diesel particulate filter) is replaced, always perform each adjustment procedure using the following steps.

STEP

ACTION

PAGE/CONDITION
1
Replace the oxidation catalytic converter.
–
2
Switch the ignition to on.
–
3
Perform diesel particulate filter data reset procedure.
(See DIESEL PARTICULATE FILTER DATA RESET [MZR-CD 2.2].)
4
Start the engine.
Verify that the MIL does not illuminate.
5
Switch the ignition to off.
–
6
Switch the ignition to on (Engine off).
–
7
Perform KOEO self-test procedure.
(See KOEO/KOER SELF TEST [MZR-CD 2.2].)
8
Perform exhaust gas pressure sensor data reset procedure.
(See EXHAUST GAS PRESSURE SENSOR DATA RESET [MZR-CD 2.2].)
9
Switch the ignition to off.
–
10
Wait for 20 s.
–
11
Start the engine.
–
12
Perform KOER self-test procedure.
Warm up until the exhaust gas temperature (EXHTEMP1, EXHTEMP2, EXHTEMP3 PID) is 100 °C {212 °F} or more.
(See KOEO/KOER SELF TEST [MZR-CD 2.2].)
13
Perform fuel injector injection amount correction procedure.
Engine coolant temperature 65—95 °C {149—203 °F}.
Intake air temperature 15—65 °C {59—149 °F}.
Fuel temperature 30—60 °C {86—140 °F}.
(See FUEL INJECTOR INJECTION AMOUNT CORRECTION [MZR-CD 2.2].)
14
Perform diesel particulate filter assessment procedure.
Engine coolant temperature 60 °C {140 °F} or more.
(See DIESEL PARTICULATE FILTER ASSESSMENT [MZR-CD 2.2].)
15
Perform diesel particulate filter regeneration procedure.
Engine coolant temperature 70 °C {158 °F} or more.
(See DIESEL PARTICULATE FILTER REGENERATION [MZR-CD 2.2].)
16
Using the following PIDs, verify that the diesel particulate filter regeneration has been completed.
― REG_REQ_A
― REG_REQ_F
(See ON-BOARD DIAGNOSTIC TEST [MZR-CD 2.2].)
17
Perform after repair procedure.
(See AFTER REPAIR PROCEDURE [MZR-CD 2.2].)
18
Switch the ignition to off.
–

Note
• If the SCR converter is replaced, always perform each adjustment procedure using the following steps.

STEP

ACTION

PAGE/CONDITION
1
Replace the SCR converter.
(See AdBlue® BLEEDING/CHARGING [MZR-CD 2.2].)
2
Start the engine.
–
3
Perform SCR converter data reset procedure.
(See SCR CONVERTER DATA RESET [MZR-CD 2.2].)
4
Switch the ignition to off.
–
5
Switch the ignition ON.
–
6
Perform after repair procedure.
(See AFTER REPAIR PROCEDURE [MZR-CD 2.2].)
7
Start the engine.
Verify that the MIL and the SCR warning light do not illuminate.
8
Switch the ignition to off.
–

1.Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

2.Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZR-CD 2.2].)

3.Remove the under cover.

4.Remove the floor under cover (RH).

5.Remove in the order indicated in the table.

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

7.Install in the reverse order of removal.

8.Start the engine and:

(1)Inspect the exhaust gas leakage.
(2)If any servicing around the turbocharger is performed, inspect around the turbocharger for oil or engine coolant leakage.

Step 1
acxwzw00001287

1
Main silencer
2
NOx sensor
(See NOX SENSOR REMOVAL/INSTALLATION [MZR-CD 2.2].)
3
SCR converter
4
SCR converter gasket and urea mixer
(See SCR Converter Gasket And Urea Mixer Installation Note.)
5
A/F sensor
(See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [MZR-CD 2.2].)
6
Exhaust gas temperature sensor
7
Middle pipe
(See Middle Pipe Removal Note.)
8
Exhaust gas pressure hose
9
Oxidation catalytic converter (built-in diesel particulate filter)
10
Turbocharger insulator
(See Turbocharger Insulator Removal Note.)
11
Front pipe bracket
12
Front pipe
13
Front pipe gasket
(See Front Pipe Gasket Installation Note.)

Step 2
acxwzw00001288

1
Oil outlet pipe
(See Oil Outlet Pipe Removal Note.)
2
Oil inlet pipe
(See Oil Inlet Pipe Installation Note.)
3
Water hose
(See Water Hose Removal Note.)
4
Water pipe
(See Water Pipe Removal Note.)
5
Turbocharger bracket No.1
6
Turbocharger
7
Turbocharger bracket No.2
8
Exhaust manifold insulator
9
Exhaust manifold
(See Exhaust Manifold Installation Note.)
10
Exhaust manifold gasket


Exhaust System Insulator Removal/Installation Note

1.Remove the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

2.Remove in the order indicated in the table.

3.Install in the reverse order of removal.
acxwzw00001289

1
Insulator (rear)
2
Insulator (front)


Middle Pipe Removal Note

1.Remove the urea injector. (See UREA INJECTOR REMOVAL/INSTALLATION [MZR-CD 2.2].)

2.Remove the middle pipe.


Turbocharger Insulator Removal Note

1.Remove the vacuum chamber component. (SeeINTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

2.Remove the turbocharger insulator.


Water Hose Removal Note

1.Drain the engine coolant. (SeeENGINE COOLANT REPLACEMENT [MZR-CD 2.2].)

2.Disconnect the water hose.


Water Pipe Removal Note

1.Remove the turbocharger air inlet pipe. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

2.Remove the turbocharger air outlet hose and turbocharger air outlet pipe as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

3.Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

4.Remove the water pipe.


Oil Outlet Pipe Removal Note

1.Remove the transfer insulator.

2.Remove the oil pan insulator.

3.Remove the joint shaft bracket.

4.Remove the front tire (RH).

5.Remove the oil outlet pipe.


Exhaust Manifold Installation Note

1.Tighten the exhaust manifold installation nuts in the order shown.
acxwzw00001290


Oil Inlet Pipe Installation Note

1.Remove the EGR cooler and EGR cooler bypass valve component. (See EGR COOLER REMOVAL/INSTALLATION [MZR-CD 2.2].)

2.Loosen the bypass pipe installation bolts.
am3zzw00007164

3.Remove the oil inlet pipe.


Front Pipe Gasket Installation Note

1.To come to position that the claw of the gasket shown in figure, it install it.
acxwzw00001291


SCR Converter Gasket And Urea Mixer Installation Note

1.Install the SCR converter gaskets and urea mixer shown in the figure.
acxwzw00001292