EXHAUST GAS TEMPERATURE SENSOR (for DPF) INSTALLATION


  1. INSTALL EXHAUST GAS TEMPERATURE SENSOR


    1. A011B2R

      Using a union nut wrench (14 mm), install the exhaust gas temperature sensor.

      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 combined with a torque wrench Click here.

  2. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. A011BJ8

      Install a new gasket onto the turbocharger.

    2. Install the exhaust manifold converter with 3 new nuts.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }
    3. A0118LRE01
      Text in Illustration
      *1 Stud Bolt
      *2 Nut

      Install the stud bolt and nut.

      Torque:
      Stud Bolt
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }
      Nut
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
    4. A011A9I

      Engage the harness camp and connect the connector.

  3. INSTALL NO. 1 AIR HOSE


    1. A0118N0E01

      Install the No. 1 air hose with the 2 hose clamps.

      Tech Tips


      • Align the paint mark of the intercooler air hose with the location mark of the turbocharger.

      • Align the paint mark of the intercooler air hose with the location mark of No. 1 air tube.

      • Make sure that the hose clamp is at the correct angle when installing.

  4. INSTALL MANIFOLD SUPPORT BRACKET


    1. A01192RE01

      Temporarily tighten the manifold support bracket with the 2 bolts and nut.

    2. Fully tighten the 2 bolts and nut, as shown in the illustration.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  5. INSTALL NO. 2 MANIFOLD SUPPORT BRACKET


    1. A011BM4

      Install the No. 2 manifold support bracket with the bolt and nut.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  6. INSTALL TAIL EXHAUST PIPE ASSEMBLY


    1. A0117GP

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

      Minimum length
      41.5 mm (1.634 in.)

      If the length is not as specified, replace the compression spring.

    2. A01175HE04

      Using a plastic hammer and a wooden block, tap in a new gasket until its surface is flush with the exhaust manifold.

      Note


      • Install the exhaust pipe gasket in the correct direction.

      • Do not damage the outer surface of the exhaust pipe gasket.

      • Do not reuse the exhaust pipe gasket.

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

    3. A0117B2

      Hang the tail exhaust pipe assembly with the 3 No. 4 exhaust pipe supports.

    4. A0119S6

      Install the tail exhaust pipe assembly with the 2 compression springs and 2 bolts.

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

  7. INSTALL TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure for the RH side as for the LH side.

  8. INSTALL FRONT WHEEL RH

  9. CONNECT SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

    A0119BD

    1. Remove the attached vinyl tape from the suction hose.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring onto the suction hose.

    4. Connect the suction hose to the cooler compressor with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  10. CONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

    A0116XX

    1. Remove the attached vinyl tape from the discharge hose.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring onto the discharge hose.

    4. Connect the discharge hose to the cooler compressor with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  11. INSTALL OIL LEVEL DIPSTICK GUIDE


    1. A0119YL

      Install the O-ring to the oil level dipstick guide.

    2. Install the oil level dipstick guide with the 2 bolts.

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

    3. Engage the harness clamp and install the oil level dipstick guide and wire harness with the bolt.

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

  12. INSTALL NO. 2 TURBO INSULATOR


    1. A011B21

      Install the No. 2 turbo insulator with the bolt and nut.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 ft.*lbf }

  13. INSTALL AIR FUEL RATIO SENSOR


    1. A011BB9E01
      Text in Illustration
      *1 Fulcrum length

      Using SST, install the air fuel ratio sensor.

      SST
      09224-00010
      Torque:
      without SST
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }
      with SST
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Note


      • The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 300 mm (11.81 in.) Click here.

      • This torque value is effective when SST is parallel to the torque wrench.

    2. A0119BY

      Engage the 3 wire harness clamps and install the air fuel ratio sensor wire harness.

    3. Connect the air fuel ratio sensor connector.

  14. INSTALL ENGINE COVER ASSEMBLY


    1. A011ACJ

      Engage the 3 claws and install the engine cover.

  15. INSTALL AIR CLEANER HOSE ASSEMBLY

    A0119ZOE02
    Text in Illustration
    *1 Paint Mark

    1. Install the air cleaner hose.

      Note

      Position the clip so that the claws are centered over the paint mark on the hose.

  16. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. A011AXX

      Install the air cleaner case with the 3 bolts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  17. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. A011BX8

      Install the air cleaner filter element.

      Note

      Engage the air cleaner filter element protrusion with the air cleaner case groove.

  18. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. A0119FRE01

      Engage the 2 claws and 2 clamps and install the air cleaner cap.

    2. Connect the connector and 2 wire harness clamps.

      Text in Illustration
      *1 Wire harness clamp
      *2 Clamp
    3. A0118S5E01

      Connect the air cleaner hose to the air cleaner cap.

      Tech Tips


      • The clamp should contact the air cleaner hose stopper.

      • Make sure that the air cleaner hose recession is securely engaged with the air cleaner cap protrusion.

  19. INSTALL FRONT WIPER MOTOR AND LINK


    1. Install the front wiper motor and link Click here.

  20. INSTALL EXHAUST PIPE (w/ Combustion Type Power Heater)


    1. Install the exhaust pipe Click here.

  21. INSTALL NO. 2 EXHAUST GAS TEMPERATURE SENSOR


    1. A0118GZ

      Using a union nut wrench (14 mm), install the No. 2 exhaust gas temperature sensor.

      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 combined with a torque wrench Click here.

    2. Engage the harness clamp.

    3. A0117R6

      Engage the harness clamp and connect the No. 2 exhaust gas temperature sensor connector.

  22. INSTALL ENGINE UNDER COVER

    A011A8B

    1. Install the engine under cover with the 4 bolts and 4 clips.

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

  23. CHARGE REFRIGERANT

  24. WARM UP ENGINE

  25. INSPECT FOR REFRIGERANT LEAK

  26. INSPECT FOR EXHAUST GAS LEAK