MONOLITHIC CONVERTER(for DPF) INSTALLATION

PROCEDURE


  1. INSTALL NO. 2 MANIFOLD CONVERTER INSULATOR


    1. Install the No. 2 manifold converter insulator with the 3 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  2. INSTALL NO. 2 VACUUM PIPE


    1. Temporarily install the No. 2 vacuum pipe with the union nut and bolt.

    2. Tighten the bolt.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    3. Using a 14 mm union nut wrench, tighten the union nut of the No. 2 vacuum pipe.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  3. INSTALL NO. 1 VACUUM PIPE


    1. Temporarily install the No. 1 vacuum pipe with the union nut and bolt.

    2. Tighten the bolt.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    3. Using a 17 mm union nut wrench, tighten the union nut of the No. 1 vacuum pipe.

      Torque:
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  4. INSTALL NO. 2 EXHAUST GAS TEMPERATURE SENSOR

    Click here

  5. INSTALL NO. 3 EXHAUST GAS TEMPERATURE SENSOR

    Click here

  6. INSTALL EXHAUST GAS TEMPERATURE SENSOR

    Click here

  7. INSTALL NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A004ORAE01
      Text in Illustration
      *1 Paint Mark (Green)
      *a Front Side of Vehicle
      *b LH Side

      Install the No. 2 vacuum transmitting hose to the No. 2 vacuum pipe.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  8. INSTALL VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A004MNEE01
      Text in Illustration
      *1 Paint Mark (Blue)
      *a Front Side of Vehicle
      *b LH Side

      Install the vacuum transmitting hose to the No. 1 vacuum pipe.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  9. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. A004TV1E02

      Install a new gasket to the turbocharger.

      Text in Illustration
      A004NPW Top

      Tech Tips

      Make sure that the part labeled A is facing downwards as shown in the illustration.

    2. Temporarily install the exhaust manifold converter with 3 new nuts.

    3. Temporarily install the No. 2 exhaust manifold stay with the 2 bolts and nut.

    4. Temporarily install the No. 2 manifold stay with the 3 bolts.

    5. Temporarily install the manifold stay with the bolt and nut.

    6. A004S31E02

      Tighten the 2 bolts of the No. 2 exhaust manifold stay in the order shown in the illustration.

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }

    7. Tighten the 3 nuts of the exhaust manifold converter.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Note

      Tighten the nuts while pressing the exhaust manifold converter against the engine.

    8. A004QJE

      Tighten the nut of the No. 2 exhaust manifold stay.

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }
    9. A004OW4

      Tighten the bolt of the No. 2 manifold stay shown in the illustration.

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }

      Note

      Tighten the bolt while pressing the No. 2 manifold stay against the exhaust manifold converter and cylinder block.

    10. A004OZM

      Tighten the 2 bolts of the No. 2 manifold stay shown in the illustration.

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }
    11. A004T86

      Tighten the bolt of the manifold stay.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Note

      Tighten the bolt while pressing the manifold stay against the exhaust manifold converter and cylinder block.

    12. A004MZW

      Tighten the nut of the manifold stay.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    13. Connect the 2 connectors.

  10. INSTALL MANIFOLD CONVERTOR INSULATOR SUB-ASSEMBLY


    1. Install the manifold converter insulator with the bolt.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

      Note

      Make sure that the ceramic wool inside the manifold converter insulator does not fall out and is not bent.

  11. INSTALL NO. 4 MANIFOLD CONVERTER INSULATOR


    1. Install the No. 4 manifold converter insulator with the 4 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  12. INSTALL ENGINE ASSEMBLY

    Click here

  13. PERFORM CATALYST RECORD OF DPF THERMAL DETERIORATION CLEAR FUNCTION

    Click here