MONOLITHIC CONVERTER REMOVAL

PROCEDURE


  1. REMOVE INTERCOOLER ASSEMBLY

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  2. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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  3. REMOVE WATER GUARD PLATE LH (for LHD)

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  4. REMOVE WATER GUARD PLATE LH (for RHD)

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  5. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)

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  6. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

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  7. REMOVE OUTER COWL TOP PANEL (for LHD)

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  8. REMOVE OUTER COWL TOP PANEL (for RHD)

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  9. REMOVE AIR FUEL RATIO SENSOR

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  10. REMOVE NO. 1 HOSE TO HOSE TUBE


    1. B0042EJC02
      *A for LHD
      *B for RHD

      Slide the clip and disconnect the check valve to connector tube hose from the No. 1 hose to hose tube.

    2. Slide the clip and disconnect the union to connector tube hose from the No. 1 hose to hose tube.

    3. B0044AOC02
      *A for LHD
      *B for RHD

      Remove the 2 nuts and No. 1 hose to hose tube from the vehicle body.

  11. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE


    1. B0044J7C02
      *a Air Cleaner Cap Sub-assembly Clamp
      *b Guide

      Disconnect the intake mass air flow meter sub-assembly connector.

    2. Disengage the wire harness from the air cleaner cap sub-assembly.

    3. Disengage the 2 air cleaner cap sub-assembly clamps.

    4. Disengage the 2 guides to separate the air cleaner cap sub-assembly from the air cleaner case sub-assembly.

    5. Loosen the hose clamp and remove the air cleaner cap with air cleaner hose from the inlet No. 1 air duct sub-assembly.

  12. REMOVE ENGINE WIRE


    1. B0042Z3C02
      B0042CO Bolt
      B0043VS Nut
      B0043HC Connector

      Disconnect the 7 connectors.

    2. Remove the bolt and nut.

    3. Disengage the 3 wire harness clamps.

    4. B004288

      Remove the 2 bolts and wire harness clamp bracket from the cylinder head sub-assembly.

  13. REMOVE VENTILATION HOSE


    1. B0043IQC02
      *1 Ventilation Hose
      *2 No. 4 Ventilation Hose

      Slide the 2 clips and remove the ventilation hose from the cylinder head cover sub-assembly and inlet No. 1 air duct sub-assembly.

    2. Slide the 2 clips and remove the No. 4 ventilation hose from the ventilation ejector and inlet No. 1 air duct sub-assembly.

  14. REMOVE VENTILATION EJECTOR


    1. B00447V

      Remove the 2 bolts and ventilation ejector from the cylinder head cover sub-assembly.

    2. Remove the O-ring from the cylinder head cover sub-assembly.

  15. REMOVE AIR TUBE ASSEMBLY


    1. B0043UMC02
      *1 No. 2 Intercooler Water Hose
      *2 No. 3 Intercooler Water Hose

      Slide the clip and disconnect the No. 2 intercooler water hose and No. 3 intercooler water hose from the turbocharger sub-assembly.

    2. B00450KC02
      *1 No. 2 Intercooler Water Hose
      *2 No. 3 Intercooler Water Hose

      Disconnect the No. 2 intercooler water hose and No. 3 intercooler water hose from the No. 1 water hose clamp bracket.

    3. B004382

      Loosen the hose clamp and remove the air tube assembly from the turbocharger sub-assembly.

    4. B0043EJ

      Remove the bolt and air tube assembly from the cylinder head cover sub-assembly.

  16. REMOVE VACUUM REGULATING VALVE ASSEMBLY


    1. B0042X8C02
      *1 No. 2 Vacuum Transmitting Hose Assembly
      *2 No. 3 Vacuum Transmitting Hose Assembly
      *3 Vacuum Regulating Valve Assembly
      *4 No. 2 Vacuum Switching Valve Bracket

      Disconnect the No. 2 vacuum transmitting hose assembly and No. 3 vacuum transmitting hose assembly from the vacuum regulating valve assembly.

    2. Remove the 3 bolts and vacuum regulating valve assembly and No. 2 vacuum switching valve bracket from the cylinder head sub-assembly.

  17. REMOVE INLET NO. 1 AIR DUCT SUB-ASSEMBLY


    1. B0043T6

      Disconnect the No. 1 vacuum transmitting hose assembly from the vacuum tank.

    2. B0044A3

      Remove the 2 bolts and vacuum tank from the inlet No. 1 air duct sub-assembly.

    3. B00453H

      Disconnect the No. 1 vacuum transmitting hose assembly from the vacuum pump assembly.

    4. B004542C01

      Remove the bolt and disconnect the inlet No. 1 air duct sub-assembly from the fuel pump protector.

    5. B0042JSC02
      *1 No. 2 Vacuum Transmitting Hose Assembly
      *2 Inlet No. 1 Air Duct Sub-assembly

      Disconnect the No. 2 vacuum transmitting hose assembly from the turbocharger sub-assembly.

    6. Loosen the hose clamp and remove the inlet No. 1 air duct sub-assembly from the turbocharger sub-assembly.

  18. REMOVE NO. 1 ENGINE COVER


    1. B0043Y6

      Remove the No. 1 engine cover from the cylinder head cover sub-assembly and cylinder head sub-assembly.

  19. REMOVE FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

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  20. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)


    1. B00431B

      Disconnect the heated oxygen sensor connector.

    2. Disengage the 2 wire harness clamps and disconnect the wire harness from the wire harness clamp bracket.

    3. B0041PN

      Remove the 4 bolts and 4 compression springs and disconnect the front exhaust pipe assembly (TWC: Rear Catalyst) from the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and tail exhaust pipe assembly.

    4. Remove the front exhaust pipe assembly (TWC: Rear Catalyst) from the 2 exhaust pipe supports.

    5. Remove the 2 exhaust pipe gaskets from the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and tail exhaust pipe assembly.

  21. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR

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  22. REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY


    1. B0042GU

      Remove the bolt, nut and drive shaft heat insulator sub-assembly from the cylinder block sub-assembly and manifold support bracket.

  23. REMOVE MANIFOLD SUPPORT BRACKET


    1. B0044HF

      Remove the bolt and manifold support bracket from the cylinder block sub-assembly and exhaust manifold converter sub-assembly (TWC: Front Catalyst).

  24. REMOVE NO. 2 TURBO INSULATOR


    1. B00435R

      Remove the 2 bolts and No. 2 turbo insulator from the cylinder head sub-assembly and heat insulator bracket.

  25. REMOVE NO. 1 MANIFOLD CONVERTER INSULATOR


    1. B004482

      Remove the 3 bolts and No. 1 manifold converter insulator from the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

  26. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)


    1. B0043O4

      Remove the 4 nuts and exhaust manifold converter sub-assembly (TWC: Front Catalyst) from the turbocharger sub-assembly.

  27. REMOVE OUTLET TURBINE ELBOW GASKET


    1. B0043WK

      Remove the outlet turbine elbow gasket from the turbocharger sub-assembly.