MONOLITHIC CONVERTER INSTALLATION

PROCEDURE


  1. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. Set a new gasket and the exhaust manifold converter sub-assembly to the turbocharger sub-assembly.

    2. Temporarily install the exhaust pipe support stay to the cylinder block sub-assembly and exhaust manifold converter sub-assembly with the 3 bolts.

    3. B001EKEE02
      Text in Illustration
      *1 Exhaust Pipe Clamp
      *2 Exhaust Manifold Converter
      *3 Turbocharger Sub-assembly
      *4 Gasket

      Install a new exhaust pipe clamp to the exhaust manifold converter sub-assembly with a new nut.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    4. Tighten the 3 bolts and install the exhaust pipe support stay to the cylinder block sub-assembly and exhaust manifold converter sub-assembly.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  2. INSTALL NO. 2 EXHAUST PIPE SUPPORT STAY


    1. Install the No. 2 exhaust pipe support stay to the cylinder block sub-assembly and exhaust manifold converter sub-assembly with the bolt and 2 new nuts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  3. INSTALL NO. 1 TURBO INSULATOR


    1. Install the No. 1 turbo insulator to the exhaust manifold and turbocharger sub-assembly with the 3 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the 3 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  5. INSTALL AIR FUEL RATIO SENSOR

    Click here

  6. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY (for RHD)

    Click here

  7. INSTALL ENGINE COVER BRACKET


    1. Install the engine cover bracket to the cylinder head sub-assembly with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    2. Attach the 2 clamps and connect the engine wire to the cylinder head sub-assembly.

  8. INSTALL PIPE CLAMP


    1. Install the pipe clamp to the engine cover bracket with the 3 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  9. TEMPORARILY INSTALL NO. 2 VACUUM PIPE


    1. Install a new clamp to the pipe clamp.

    2. Temporarily install the No. 2 vacuum pipe to the exhaust manifold converter sub-assembly.

  10. TEMPORARILY INSTALL NO. 1 VACUUM PIPE


    1. Temporarily install the No. 1 vacuum pipe to the exhaust manifold converter sub-assembly.

    2. Install a new clamp to the No. 1 vacuum pipe and No. 2 vacuum pipe with the nut.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  11. TIGHTEN NO. 2 VACUUM PIPE


    1. B001HNFE01
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      Using a 17 mm union nut wrench, tighten the No. 2 vacuum pipe.

      Torque
      Specified tightening torque
      48 N*m {489 kgf*cm, 35 ft.*lbf}

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

      • When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 255 mm (10.0 in.)): 43 N*m (437 kgf*cm, 32 ft.*lbf)

  12. TIGHTEN NO. 1 VACUUM PIPE


    1. B001HNFE01
      Text in Illustration
      *a Torque Wrench Fulcrum Length

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

      Torque
      Specified tightening torque
      48 N*m {489 kgf*cm, 35 ft.*lbf}

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

      • When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 255 mm (10.0 in.)): 43 N*m (437 kgf*cm, 32 ft.*lbf)

  13. INSTALL EXHAUST GAS TEMPERATURE SENSOR

    Click here

  14. INSTALL NO. 3 ENGINE COVER BRACKET

    Click here

  15. INSTALL DIFFERENTIAL PRESSURE SENSOR

    Click here

  16. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  17. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  18. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE

    Click here

  19. INSTALL NO. 1 FRONT FENDER APRON TO FRAME SEAL RH

    Click here

  20. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  21. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  22. BLEED AIR FROM FUEL SYSTEM

    Click here

  23. ADD ENGINE COOLANT

    Click here

  24. INSPECT FOR COOLANT LEAK

    Click here