MONOLITHIC CONVERTER INSTALLATION
PROCEDURE
INSTALL OUTLET TURBINE ELBOW GASKET
Install a new outlet turbine elbow gasket to the turbocharger sub-assembly.
INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)
Temporarily install the exhaust manifold converter sub-assembly (TWC: Front Catalyst) to the turbocharger sub-assembly with 4 new nuts.
-
Tighten the 4 nuts in the order shown in the illustration.
40 N*m
408 kgf*cm
30 ft.*lbf
INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR
Temporarily install the No. 1 manifold converter insulator to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 3 bolts.
-
Tighten the 3 bolts in the order shown in the illustration.
10 N*m
102 kgf*cm
7 ft.*lbf
INSTALL NO. 2 TURBO INSULATOR
Temporarily install the No. 2 turbo insulator to the cylinder head sub-assembly and heat insulator bracket with the 2 bolts.
-
Tighten the 2 bolts in the order shown in the illustration.
10 N*m
102 kgf*cm
7 ft.*lbf
INSTALL MANIFOLD SUPPORT BRACKET
Install the manifold support bracket to the cylinder block sub-assembly and exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 3 bolts.
40 N*m
408 kgf*cm
30 ft.*lbf
INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY
Temporarily install the drive shaft heat insulator sub-assembly to the cylinder block sub-assembly and manifold support bracket with the bolt and nut.
-
Tighten the bolt and nut in the order shown in the illustration.
17.6 N*m
179 kgf*cm
13 ft.*lbf
INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR
INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)
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Using a vernier caliper, measure the free length of the compression springs.
Standard Length
Front Side
43 mm (1.69 in.)
Rear Side
40 mm (1.57 in.)
Minimum Free Length
Front Side
41.5 mm (1.63 in.)
Rear Side
38.5 mm (1.52 in.)
If the free length is less than the minimum, replace the compression spring.
Temporarily install 2 new exhaust pipe gasket to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst).
-
*1
Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst) or Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
*2
Exhaust Pipe Gasket
*a
Wooden Block
Using a plastic hammer and wooden block, tap in the exhaust pipe gasket until its surface is flush with the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst).
Note:Be sure to install the exhaust pipe gasket in the correct direction.
Do not reuse the exhaust pipe gasket.
Do not damage the exhaust pipe gasket.
Do not push in the exhaust pipe gasket by using the exhaust pipe when connecting it.
Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and tail exhaust pipe assembly with the 4 compression springs and 4 bolts.
43 N*m
438 kgf*cm
32 ft.*lbf
Tip:
*1
Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst) or Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
*2
Front Exhaust Pipe Assembly (TWC: Rear Catalyst) or Tail Exhaust Pipe Assembly
*3
Exhaust Pipe Gasket
*a
Space between Flanges:
- Front Side: 8.5 mm (0.335 in.)
- Rear Side: 6.5 mm (0.256 in.)
After installation, check that the space between the flanges of the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst) is consistent front-to-rear and left-to-right.
After installation, check that the space between the flanges of the front exhaust pipe assembly (TWC: Rear Catalyst) and tail exhaust pipe assembly is consistent front-to-rear and left-to-right.
Engage the 2 wire harness clamps.
Connect the heated oxygen sensor connector.
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INSTALL FRONT CENTER FLOOR BRACE SUB-ASSEMBLY
INSTALL NO. 1 ENGINE COVER
Install the No. 1 engine cover to the cylinder head cover sub-assembly and cylinder head sub-assembly.
INSTALL INLET NO. 1 AIR DUCT SUB-ASSEMBLY
Connect the inlet No. 1 air duct sub-assembly to the turbocharger sub-assembly.
Tighten the hose clamp.
4.0 N*m
41 kgf*cm
35 in.*lbf
Connect the No. 2 vacuum transmitting hose assembly to the turbocharger sub-assembly.
Connect the inlet No. 1 air duct sub-assembly to the fuel pump protector with the bolt.
10 N*m
102 kgf*cm
7 ft.*lbf
Connect the No. 1 vacuum transmitting hose assembly to the vacuum pump assembly.
Install the vacuum tank to the inlet No. 1 air duct sub-assembly with the 2 bolts.
9.0 N*m
92 kgf*cm
80 in.*lbf
Connect the No. 1 vacuum transmitting hose assembly to the vacuum tank.
INSTALL VACUUM REGULATING VALVE ASSEMBLY
Connect the No. 2 vacuum transmitting hose assembly and No. 3 vacuum transmitting hose assembly to the vacuum regulating valve assembly.
Install the vacuum regulating valve assembly and No. 2 vacuum switching valve bracket to the cylinder head sub-assembly with the 3 bolts.
10 N*m
102 kgf*cm
7 ft.*lbf
INSTALL AIR TUBE ASSEMBLY
Install the air tube assembly to the cylinder head cover sub-assembly with the bolt.
10 N*m
102 kgf*cm
7 ft.*lbf
Connect the air tube assembly to the turbocharger sub-assembly.
Tighten the hose clamp.
6.3 N*m
64 kgf*cm
56 in.*lbf
Connect the No. 2 intercooler water hose and No. 3 intercooler water hose to the No. 1 water hose clamp bracket.
Connect the No. 2 intercooler water hose and No. 3 intercooler water hose to the turbocharger sub-assembly and slide the clip to secure it.
INSTALL VENTILATION EJECTOR
Apply a light coat of engine oil to the O-ring.
Note:When reusing the ventilation ejector, inspect the O-ring.
Install the O-ring to the cylinder head cover sub-assembly.
Install the ventilation ejector to the cylinder head cover sub-assembly with the 2 bolts.
10 N*m
102 kgf*cm
7 ft.*lbf
INSTALL VENTILATION HOSE
Install the ventilation hose to the cylinder head cover sub-assembly and inlet No. 1 air duct sub-assembly and slide the 2 clips to secure it.
Install the No. 4 ventilation hose to the ventilation ejector and inlet No. 1 air duct sub-assembly and slide the 2 clips to secure it.
INSTALL ENGINE WIRE
Using a 10 mm deep socket wrench, install the wire harness clamp bracket to the cylinder head sub-assembly with the 2 bolts.
10 N*m
102 kgf*cm
7 ft.*lbf
-
Bolt
Nut
Connector
Engage the 3 wire harness clamps.
Install the bolt and nut.
10 N*m
102 kgf*cm
7 ft.*lbf
Connect the 7 connectors.
INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE
-
*a
Air Cleaner Cap Sub-assembly Clamp
*b
Guide
*c
Upper
*d
RH
*e
Stopper
*f
Protrusion
*g
Cutout
Connect the air cleaner cap with air cleaner hose to the inlet No. 1 air duct sub-assembly.
Note:Align the cutout of the air cleaner hose assembly with the protrusion of the inlet No. 1 air duct sub-assembly.
Tighten the hose clamp in the position shown in the illustration.
2.0 N*m
20 kgf*cm
18 in.*lbf
Engage the 2 guides to install the air cleaner cap sub-assembly to the air cleaner case sub-assembly.
Engage the 2 air cleaner cap sub-assembly clamps to install the air cleaner cap sub-assembly.
Engage the wire harness to the air cleaner cap sub-assembly.
Connect the intake mass air flow meter sub-assembly connector.
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INSTALL NO. 1 HOSE TO HOSE TUBE
Install the No. 1 hose to hose tube to the vehicle body with the 2 nuts.
5.4 N*m
55 kgf*cm
48 in.*lbf
Connect the union to connector tube hose to the No. 1 hose to hose tube and slide the clip to secure it.
Connect the check valve to connector tube hose to the No. 1 hose to hose tube and slide the clip to secure it.
INSTALL AIR FUEL RATIO SENSOR
INSTALL OUTER COWL TOP PANEL (for LHD)
INSTALL OUTER COWL TOP PANEL (for RHD)
INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)
INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)
INSTALL WATER GUARD PLATE LH (for LHD)
INSTALL WATER GUARD PLATE LH (for RHD)
INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
INSTALL INTERCOOLER ASSEMBLY
INSPECT FOR EXHAUST GAS LEAK
If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.
Perform Inspection After Repair after repairing an exhaust gas leak.