EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2]

• 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 (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 KOEO self-test procedure.

Warm up until the exhaust gas temperature (EXHTEMP1, EXHTEMP2 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.

–

1	Main silencer
2	Middle pipe
3	A/F sensor (See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [MZR-CD 2.2])
4	Exhaust gas temperature sensor
5	Exhaust gas pressure hose
6	Oxidation catalytic converter (built-in diesel particulate filter) (SeeFlange Surface Installation Note.)
7	Seal ring (front pipe side) (See Seal Ring Removal Note.) (See Seal Ring Installation Note (Front Pipe Side).)
8	Front pipe (See Flange Surface Installation Note.)
9	Seal ring (joint pipe side) (See Seal Ring Removal Note.) (See Seal Ring Installation Note (Joint Pipe Side).)
10	Joint pipe bracket
11	Joint pipe (See Joint Pipe Removal Note.) (See Flange Surface Installation Note.)

1	Joint pipe gasket (See Joint Pipe Gasket Installation Note.)
2	Exhaust manifold insulator (lower)
3	Exhaust manifold insulator (upper) (See Exhaust Manifold Insulator (Upper) Removal Note.)
4	Oil inlet pipe
5	Oil outlet pipe
6	Water hose
7	Turbocharger (See Turbocharger Removal Note.)
8	Water pipe (See Water Pipe Removal Note.)
9	Exhaust manifold (See Exhaust Manifold Removal Note.) (See Exhaust Manifold Installation Note.)
10	Exhaust manifold gasket

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 KOEO self-test procedure.	Warm up until the exhaust gas temperature (EXHTEMP1, EXHTEMP2 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.	–

1	Insulator (front)
2	Insulator (middle)
3	Insulator (rear) (See Insulator (rear) removal note)