MONOLITHIC CONVERTER(w/ DPF) REMOVAL

CAUTION / NOTICE / HINT

PROCEDURE

1. DRAIN ENGINE COOLANT

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2. REMOVE FRONT EXHAUST PIPE ASSEMBLY

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3. REMOVE FUEL ADDITION INJECTOR ASSEMBLY

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4. REMOVE FRONT FENDER SEAL

   
   

   1. for 2WD:

      Remove the 5 clips and front fender seal from the body.

   2. for 4WD and Pre-Runner:

      Remove the 6 clips and front fender seal from the body.

5. REMOVE AIR CLEANER CAP AND HOSE

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6. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

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7. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

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8. REMOVE DIFFERENTIAL PRESSURE SENSOR

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9. REMOVE EXHAUST GAS TEMPERATURE SENSOR

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10. REMOVE NO. 1 VACUUM PIPE

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

    
    

    1. 

       Remove the nut and clamp from the No. 1 vacuum pipe and No. 2 vacuum pipe.

    2. 

       Using a 17 mm union nut wrench, remove the No. 1 vacuum pipe from the exhaust manifold converter sub-assembly.

11. REMOVE NO. 2 VACUUM PIPE

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

    
    

    1. 

       Using a 17 mm union nut wrench, remove the No. 2 vacuum pipe from the exhaust manifold converter sub-assembly.

    2. 

       Remove the clamp from the pipe clamp.

12. REMOVE PIPE CLAMP

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

    
    

    1. 

       Remove the 3 bolts and pipe clamp from the engine cover bracket.

13. REMOVE ENGINE COVER BRACKET

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

    
    

    1. 

       Detach the 2 clamp and disconnect the engine wire from the engine cover bracket.

    2. 

       Remove the 2 bolts and engine cover bracket from the cylinder head sub-assembly.

14. REMOVE NO. 2 INTERMEDIATE SHAFT SUB-ASSEMBLY (for RHD)

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15. REMOVE UPPER ARM BUSH HEAT INSULATOR

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

    
    

    1. 

       Remove the 2 bolt and upper arm bush heat insulator from the body.

16. REMOVE AIR FUEL RATIO SENSOR

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17. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

    
    

    1. 

       Remove the 3 bolts and No. 1 exhaust manifold heat insulator from the exhaust manifold.

18. REMOVE NO. 1 TURBO INSULATOR

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

    
    

    1. 

       Remove the 3 bolts and No. 1 turbo insulator from the exhaust manifold and turbocharger sub-assembly.

19. REMOVE NO. 2 EXHAUST PIPE SUPPORT STAY

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

    
    

    1. 

       Remove the bolt, 2 nuts and No. 2 exhaust pipe support stay from the cylinder block sub-assembly and exhaust manifold converter sub-assembly.

20. REMOVE EXHAUST PIPE SUPPORT STAY

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

    
    

    1. 

       Remove the 3 bolts and exhaust pipe support stay from the cylinder block sub-assembly and exhaust manifold converter sub-assembly.

21. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

    
    

    1. 

       Remove the nut, exhaust pipe clamp and exhaust manifold converter sub-assembly from the turbocharger sub-assembly.

    2. Remove the gasket.