EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD (RF Turbo)]

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  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 WDS or equivalent before removing parts. If any DTCs are displayed, perform troubleshooting according to the corresponding DTC inspection. (See DTC TABLE [MZR-CD (RF Turbo)].) (See SYMPTOM DIAGNOSTIC INDEX [MZR-CD (RF Turbo)].)
  • 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 (RF Turbo)].)
  • If the oxidation catalytic converter (diesel particulate filter) or A/F sensor, or both are replaced, always perform each adjustment procedure using the following steps.

  STEP | ACTION | PAGE/CONDITION
  --- | --- | ---
  1 | Replace the oxidation catalytic converter. | –
  2 | Turn the engine switch on. | –
  3 | Perform diesel particulate filter data reset procedure. | (See DIESEL PARTICULATE FILTER DATA RESET [MZR-CD (RF Turbo)].)
  4 | Start the engine. | Verify that the MIL does not illuminate.
  5 | Turn the engine switch off. | –
  6 | Turn the engine switch on (Engine off). | –
  7 | Perform KOEO self-test procedure. | (See KOEO/KOER SELF TEST [MZR-CD (RF Turbo)].)
  8 | Perform diesel particulate filter reset procedure. | –
  9 | Turn the engine switch 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 (RF Turbo)].)
  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 ENGINE TUNE-UP [MZR-CD (RF Turbo)].)
  14 | Perform diesel particulate filter assessment procedure. | Engine coolant temperature 60 °C {140 °F} or more. (See DIESEL PARTICULATE FILTER ASSESSMENT [MZR-CD (RF Turbo)].)
  15 | Perform diesel particulate filter regeneration procedure. | Engine coolant temperature 70 °C {158 °F} or more. (See DIESEL PARTICULATE FILTER REGENERATION [MZR-CD (RF Turbo)].)
  16 | Perform after repair procedure. | (See AFTER REPAIR PROCEDURE [MZR-CD (RF Turbo)].)
  17 | Turn the engine switch off. | –

1. Disconnect the negative battery cable.

2. Remove the engine cover.

3. Remove in the order indicated in the table.

4. Install in the reverse order of removal.

5. 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.

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1 | Main silencer
2 | Exhaust gas pressure hose
3 | Oxidation catalytic converter (built-in diesel particulate filter)
4 | A/F sensor (See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [MZR-CD (RF Turbo)])
5 | Exhaust gas temperature sensor (See Exhaust Gas Temperature Sensor Installation Note)
6 | Turbocharger insulator No.1
7 | Turbocharger insulator No.2
8 | Exhaust manifold insulator
9 | Front pipe bracket No.1 (See Front Pipe Installation Note)
10 | Front pipe bracket No.2 (See Front Pipe Installation Note)
11 | Front pipe (See Front Pipe Installation Note)
12 | Oil pipe (supply) (See Oil Pipe (Supply) Installation Note)
13 | Water pipe (See Water Pipe Removal Note) (See Water Pipe Installation Note)
14 | Oil pipe (return)
15 | Turbocharger bracket
16 | Turbocharger (See Turbocharger Removal Note)
17 | Exhaust manifold (See Exhaust Manifold Removal Note) (See Exhaust Manifold Installation Note)

Water Pipe Removal Note

1. Drain the engine coolant before removing the water pipe. (See ENGINE COOLANT REPLACEMENT [MZR-CD (RF Turbo)].)

Turbocharger Removal Note

1. Remove the battery. (See BATTERY REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

2. Remove the fuel filter component with the hose still connected. Position the fuel filter component so that it is out of the way. (R.H.D.) (See FUEL FILTER COMPONENT REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

Exhaust Manifold Removal Note

1. Remove the EGR cooler before removing the exhaust manifold. (See EGR COOLER REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

Exhaust Manifold Installation Note

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

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2. Install the EGR cooler. (See EGR COOLER REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

Water Pipe Installation Note

1. Tighten the water pipe installation nuts in the order shown.

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2. Refill the engine coolant after Installing the water pipe. (See ENGINE COOLANT REPLACEMENT [MZR-CD (RF Turbo)].)

Oil Pipe (Supply) Installation Note

1. Tighten the Oil pipe (supply) installation bolts in the order shown.

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Front Pipe Installation Note

1. Tighten the bolts A.

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  Tightening torque:

  B, E: 22—29 N·m {2.3—2.9 kgf·m, 17—21 ft·lbf}

  A, C, D: 38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

2. Tighten the bolt B and nuts E.

3. Verify that brackets X, Y and Z are each properly installed.

4. Tighten the bolts C.

5. Tighten the bolts D.

Exhaust Gas Temperature Sensor Installation Note

1. Remove the burn protection agent from the installation hole of the exhaust gas temperature sensor.

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2. Apply the burn protection agent to the threads of the nuts and the exhaust gas temperature sensor, and tighten the sensor and nuts in the order shown in the figure.

  Tightening torque:

  Exhaust gas temperature sensor: 25—35 N·m {2.6—3.5 kgf·m, 19—25 ft·lbf}

  Nuts: 6.9—9.8 N·m {71—99 kgf·cm, 61—86 in·lbf}