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 click here 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 click here combined with a torque wrench.

      Click here

  4. INSTALL EXHAUST GAS TEMPERATURE SENSOR

    Click here

  5. INSTALL NO. 2 EXHAUST GAS TEMPERATURE SENSOR

    Click here

  6. INSTALL NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01V79EC01
      *1 Paint Mark (Green)
      *a LH Side
      A01V8SA Front Side of The Vehicle

      Install the No. 2 vacuum transmitting hose assembly to the No. 2 vacuum pipe, and slide the clamp to secure the hose.

      Tech Tips

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

  7. INSTALL VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01V8UTC01
      *1 Paint Mark (Light Blue)
      *a LH Side
      A01V8SA Front Side of The Vehicle

      Install the vacuum transmitting hose assembly to the No. 1 vacuum pipe, and slide the clamp to secure the hose.

      Tech Tips

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

  8. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. Install a new gasket to the turbocharger sub-assembly.

      Tech Tips

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

      A01V738C03
      A01V9RL Top
    2. A01V8CB

      Temporarily install the exhaust manifold converter sub-assembly with the 3 new nuts.

    3. A01V8SO

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

    4. A01V90E

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

    5. A01V9WH

      Temporarily install the manifold stay with the bolt and nut.

    6. A01V7NYN02

      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 sub-assembly.

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

      Note

      Tighten the nuts while pressing the exhaust manifold converter sub-assembly against the engine.

    8. A01V70Z

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

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }
    9. A01V96X

      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 sub-assembly and cylinder block sub-assembly.

    10. A01V9WM

      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. A01VADL

      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 sub-assembly and cylinder block sub-assembly.

    12. A01V84E

      Tighten the nut of the manifold stay.

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

    13. Connect the exhaust temperature sensor connector and No. 2 exhaust temperature sensor connector.

  9. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR


    1. Install the No. 1 manifold converter insulator with the 5 bolts.

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

  10. INSTALL ENGINE ASSEMBLY

    Click here

  11. PERFORM CATALYST RECORD OF DPF THERMAL DETERIORATION CLEAR FUNCTION

    Click here