MONOLITHIC CONVERTER INSTALLATION

Info Added 2017-10-06

PROCEDURE


  1. INSTALL OUTLET TURBINE ELBOW GASKET


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

  2. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)


    1. Temporarily install the exhaust manifold converter sub-assembly (TWC: Front Catalyst) to the turbocharger sub-assembly with 4 new nuts.

    2. A001XRFC02
      *A for 2WD
      *B for AWD

      Tighten the 4 nuts in the order shown in the illustration.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  3. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR (for 2WD)


    1. Temporarily install the No. 1 manifold converter insulator to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 3 bolts.

    2. A001WHJN01

      Tighten the 3 bolts in the order shown in the illustration.

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

  4. INSTALL NO. 2 TURBO INSULATOR


    1. Temporarily install the No. 2 turbo insulator to the cylinder head sub-assembly and heat insulator bracket with the 2 bolts.

    2. A001WZDN02

      Tighten the 2 bolts in the order shown in the illustration.

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

  5. INSTALL NO. 2 MANIFOLD CONVERTER INSULATOR (for AWD)


    1. A001XNCN01

      Temporarily install the No. 2 manifold converter insulator to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 3 bolts.

    2. Tighten the 3 nuts in the order shown in the illustration.

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

  6. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR (for AWD)


    1. A001XIIN01

      Temporarily install the No. 1 manifold converter insulator to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with 4 bolts.

    2. Tighten the 4 bolts in the order shown in the illustration.

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

  7. INSTALL PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY (for AWD)


    1. A001UVQN01

      Temporarily install the propeller shaft heat insulator bracket sub-assembly to the transfer assembly with the 2 bolts.

    2. Tighten the 2 bolts in the order shown in the illustration.

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

  8. INSTALL PROPELLER SHAFT HEAT INSULATOR (for AWD)


    1. A001VSNN01

      Temporarily install the propeller shaft heat insulator to the transfer assembly with the 3 bolts.

    2. Tighten the 3 bolts in the order shown in the illustration.

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

  9. INSTALL MANIFOLD SUPPORT BRACKET (for AWD)


    1. A001SZAC01
      *1 Bolt (A)
      *2 Bolt (B)

      Temporarily install the manifold support bracket to the cylinder block sub-assembly and exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 3 bolts.

    2. Temporarily tighten the 2 bolts (A).

    3. Tighten the bolt (B).

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

    4. Tighten the 2 bolts (A).

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  10. INSTALL MANIFOLD SUPPORT BRACKET (for 2WD)


    1. Install the manifold support bracket to the cylinder block sub-assembly and exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 3 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  11. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY (for 2WD)


    1. Temporarily install the drive shaft heat insulator sub-assembly to the cylinder block sub-assembly and manifold support bracket with the bolt and nut.

    2. A001UN5N02

      Tighten the bolt and nut in the order shown in the illustration.

      Torque:
      17.6 N*m  { 179 kgf*cm, 13 ft.*lbf }

  12. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR


    1. Install the front No. 1 floor heat insulator to the vehicle body with 3 nuts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  13. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) (for 2WD)


    1. A001TUM

      Using a vernier caliper, measure the free length of the compression springs.

      Standard Length Front Side 43 mm (1.69 in.)
      Rear Side 40 mm (1.57 in.)
      Minimum Free Length Front Side 41.5 mm (1.63 in.)
      Rear Side 38.5 mm (1.52 in.)

      If the free length is less than the minimum, replace the compression spring.

    2. Temporarily install 2 new exhaust pipe gasket to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst).

    3. A001SKJC96
      *1 Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst) or Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *2 Exhaust Pipe Gasket
      *a Wooden Block

      Using a plastic hammer and wooden block, tap in the exhaust pipe gasket until its surface is flush with the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst).

      Note


      • Be sure to install the exhaust pipe gasket in the correct direction.

      • Do not reuse the exhaust pipe gasket.

      • Do not damage the exhaust pipe gasket.

      • Do not push in the exhaust pipe gasket by using the exhaust pipe when connecting it.

    4. Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and tail exhaust pipe assembly with the 4 compression springs and 4 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Tech Tips


      • After installation, check that the space between the flanges of the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst) is consistent front-to-rear and left-to-right.

      • After installation, check that the space between the flanges of the front exhaust pipe assembly (TWC: Rear Catalyst) and tail exhaust pipe assembly is consistent front-to-rear and left-to-right.

      A001V8WC38
      *1 Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst) or Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
      *2 Front Exhaust Pipe Assembly (TWC: Rear Catalyst) or Tail Exhaust Pipe Assembly
      *3 Exhaust Pipe Gasket
      *a

      Space between Flanges:

      - Front Side: 8.5 mm (0.335 in.)

      - Rear Side: 6.5 mm (0.256 in.)

    5. Engage the wire harness clamp.

    6. Connect the heated oxygen sensor connector.

  14. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for AWD)


    1. Temporarily install new exhaust pipe gasket to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and front exhaust pipe assembly.

    2. Install the front exhaust pipe assembly to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with 2 new nuts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

    3. Engage the wire harness clamp.

    4. Connect the heated oxygen sensor connector.

  15. INSTALL NO. 2 CENTER EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) (for AWD)


    1. Temporarily install 2 new exhaust pipe gaskets to the front exhaust pipe assembly and tail exhaust pipe assembly.

    2. Connect the No. 2 center exhaust pipe assembly (TWC: Rear Catalyst) to the 4 exhaust pipe supports.

    3. Install the No. 2 center exhaust pipe assembly (TWC: Rear Catalyst) to the front exhaust pipe assembly and tail exhaust pipe assembly with the 4 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  16. INSTALL FRONT FLOOR CENTER BRACE


  17. INSTALL FRONT FLOOR COVER LH (w/ Cover)


  18. INSTALL FRONT FLOOR COVER RH (w/ Cover)

    Tech Tips

    Perform the same procedure as for the front floor cover LH.

  19. INSTALL NO. 1 ENGINE COVER


    1. Install the No. 1 engine cover to the cylinder head cover sub-assembly and cylinder head sub-assembly.

  20. INSTALL AIR FUEL RATIO SENSOR

    Click here

  21. INSTALL INLET NO. 1 AIR DUCT SUB-ASSEMBLY


    1. Connect the inlet No. 1 air duct sub-assembly to the turbocharger sub-assembly.

    2. Tighten the hose clamp.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    3. Connect the No. 2 vacuum transmitting hose assembly to the turbocharger sub-assembly.

    4. Connect the intake air control valve (air by-pass valve assembly) connector.

    5. Connect the inlet No. 1 air duct sub-assembly to the fuel pump protector with the bolt.

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

    6. Connect the No. 1 vacuum transmitting hose assembly to the vacuum pump assembly.

    7. Install the vacuum tank to the inlet No. 1 air duct sub-assembly with the 2 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    8. Connect the No. 1 vacuum transmitting hose assembly to the vacuum tank.

  22. INSTALL VACUUM REGULATING VALVE ASSEMBLY


    1. Connect the No. 2 vacuum transmitting hose and No. 3 vacuum transmitting hose to the vacuum regulating valve assembly.

    2. Install the vacuum regulating valve assembly and No. 2 vacuum switching valve bracket to the cylinder head sub-assembly with the 3 bolts.

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

  23. INSTALL AIR TUBE ASSEMBLY


    1. Connect the air tube assembly to the turbocharger sub-assembly.

    2. Tighten the hose clamp.

      Torque:
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }

    3. Connect the No. 2 intercooler water hose and No. 3 intercooler water hose to the No. 1 water hose clamp bracket.

    4. Connect the No. 2 intercooler water hose and No. 3 intercooler water hose to the turbocharger sub-assembly and slide the 2 clips to secure them.

  24. INSTALL VENTILATION EJECTOR


    1. Apply a light coat of engine oil to the O-ring.

      Note

      When reusing the ventilation ejector, inspect the O-ring.

    2. Install the O-ring to the cylinder head cover sub-assembly.

    3. A001SB9

      Install the ventilation ejector and air tube assembly to the cylinder head cover sub-assembly with the 3 bolts.

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

  25. INSTALL VENTILATION HOSE


    1. Install the ventilation hose to the cylinder head cover sub-assembly and inlet No. 1 air duct sub-assembly and slide the 2 clips to secure it.

    2. Install the No. 4 ventilation hose to the ventilation ejector and inlet No. 1 air duct sub-assembly and slide the 2 clips to secure it.

  26. INSTALL ENGINE WIRE


    1. Install the wire harness clamp bracket to the cylinder head sub-assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A001TG2C03
      B00495X Bolt
      B0049DE Nut
      A001UHL Connector

      Engage the 3 wire harness clamps.

    3. Install the bolt and nut.

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

    4. Connect the 7 connectors.

  27. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

  28. INSTALL NO. 1 AIR CLEANER INLET

    Click here

  29. INSTALL RADIATOR COVER

    Click here

  30. INSTALL DASH PANEL HEAT INSULATOR


  31. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)

    Click here

  32. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)

    Click here

  33. INSTALL COWL BODY MOUNTING REINFORCEMENT RH

    Click here

  34. INSTALL COWL BODY MOUNTING REINFORCEMENT LH

    Click here

  35. INSTALL WATER GUARD PLATE LH

    Click here

  36. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

    Click here

  37. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  38. INSTALL INTERCOOLER ASSEMBLY

    Click here

  39. INSPECT FOR EXHAUST GAS LEAK

    If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.


    1. Perform Inspection After Repair after repairing an exhaust gas leak.

      Click here