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.
•  If the oxidation catalytic converter (built-in diesel particulate filter), joint pipe, or front pipe is reused, sand the flange surface and remove sanding residue, accumulated matter, and friction marks before installing the seal ring.
•  If this work is not performed, the seal ring may not be installed correctly. When sanding the flange surface, be careful not to damage the surface.
•  When sanding the flange surface, sanding residue may get into the removed part or pipe resulting in deterioration or damage to the part. When sanding, make sure parts are protected from sanding residue or foreign matter penetration.
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 (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) 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 (RF Turbo)].)
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 (RF Turbo)].)
8
Perform exhaust gas pressure sensor data reset procedure.
(See EXHAUST GAS PRESSURE SENSOR DATA RESET [MZR-CD (RF Turbo)].)
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 (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 FUEL INJECTOR INJECTION AMOUNT CORRECTION [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
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 (RF Turbo)].)
17
Perform after repair procedure.
(See AFTER REPAIR PROCEDURE [MZR-CD (RF Turbo)].)
18
Switch the ignition to off.
–

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

2.  Remove the engine cover.

3.  Remove in the order indicated in the table.

4.  Remove the insulator. (See Exhaust System Insulator Removal/installation Note.)

5.  Install in the reverse order of removal.

6.  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
Tunnel member
2
Main silencer
3
Middle pipe
4
Exhaust gas pressure hose
5
Oxidation catalytic converter (built-in diesel particulate filter)
(See Flange Surface Installation Note.)
6
Seal ring (joint pipe side)
(See Seal Ring Removal Note.)
(See Seal Ring Installation Note (Joint Pipe Side).)
7
A/F sensor
(See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [MZR-CD (RF Turbo)])
8
Exhaust gas temperature sensor
9
Joint pipe
(See Flange Surface Installation Note.)
10
Seal ring (front pipe side)
(See Seal Ring Removal Note.)
(See Seal Ring Installation Note (Front Pipe Side).)
11
Turbocharger insulator No.1
12
Front pipe bracket No.1
(See Front Pipe Installation Note)
13
Front pipe bracket No.2
(See Front Pipe Installation Note)
14
Front pipe
(See Front Pipe Installation Note)
15
Oil pipe (supply)
(See Oil Pipe (Supply) Installation Note)
16
Water pipe
(See Water Pipe Removal Note)
(See Water Pipe Installation Note)
17
Oil pipe (return)
18
Turbocharger bracket
19
Turbocharger insulator No.2
20
Exhaust manifold insulator
21
Turbocharger
(See Turbocharger Removal Note)
22
Exhaust manifold
(See Exhaust Manifold Removal Note)
(See Exhaust Manifold Installation Note)
23
Tailpipe garnish
(See Tailpipe Garnish Replacement Note)


Exhaust System Insulator Removal/installation Note

Note
•  Refer to the “FUEL TANK REMOVAL/INSTALLATION, Rivet Removal Note” when removing the rivets installed to the insulator.

1.  Remove the exhaust system insulator in the order shown in the figure.

2.  Install in the reverse order of removal.

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1
Insulator (front)
2
Insulator (middle)
3
Insulator (rear)
(See FUEL TANK REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)


Seal Ring Removal Note

1.  Remove the seal ring using a flathead screwdriver being careful not to damage the pipe.

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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)].)


Exhaust Manifold Removal Note

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


Tailpipe Garnish Replacement Note

Note
•  Only the tailpipe garnish can be replaced using the following procedure if it has been damaged (for Europe only).

1.  Remove the spot welding on the damaged tailpipe garnish.

2.  Install a new tailpipe garnish as shown in the figure.

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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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Flange Surface Installation Note

Caution
•  If the oxidation catalytic converter (built-in diesel particulate filter), joint pipe, or front pipe is reused, sand the flange surface and remove sanding residue, accumulated matter, and friction marks before installing the seal ring.
•  If this work is not performed, the seal ring may not be installed correctly. When sanding the flange surface, be careful not to damage the surface.
•  When sanding the flange surface, sanding residue may get into the removed part or pipe resulting in deterioration or damage to the part. When sanding, make sure parts are protected from sanding residue or foreign matter penetration.

1.  Sand the surface shown in the figure using sandpaper and remove sanding residue, accumulated matter, and friction marks.

2.  Degrease the sanded surface.

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Front Pipe Installation Note

1.  Tighten the bolts A.

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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.

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}

Seal Ring Installation Note (Front Pipe Side)

Caution
•  If the front pipe, or joint pipe is reused, sand the flange surface and remove sanding residue, accumulated matter, and friction marks before installing the seal ring. If this work is not performed, the seal ring may not be installed correctly. (See Flange Surface Installation Note.)
•  If installation is performed without using the SST, the seal ring will be damaged and deformed, resulting in an incorrect installation. Always use the SST to install the seal ring.

1.  Temporarily install the seal ring to the pipe so that the seal ring is even with the flange.

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2.  Install the SST to the seal ring so that the SST is even with the flange.

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3.  Press in the seal ring by tapping the SST using a plastic hammer until the seal ring contacts the flange.

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Seal Ring Installation Note (Joint Pipe Side)

Caution
•  If the joint pipe or oxidation catalytic converter (built-in diesel particulate filter) is reused, sand the flange surface and remove sanding residue, accumulated matter, and friction marks before installing the seal ring. If this work is not performed, the seal ring may not be installed correctly. (See Flange Surface Installation Note.)
•  If installation is performed without using the SST, the seal ring will be damaged and deformed, resulting in an incorrect installation. Always use the SST to install the seal ring.

1.  Temporarily install the seal ring to the pipe so that the seal ring is even with the flange.

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2.  Install the SST to the seal ring so that the SST is even with the flange.

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3.  Press in the seal ring by tapping the SST using a plastic hammer until the seal ring contacts the flange.

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