MONOLITHIC CONVERTER (for DPF) INSTALLATION


  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 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 combined with a torque wrench Click here.

  4. INSTALL NO. 2 EXHAUST GAS TEMPERATURE SENSOR

    Note

    If the No. 2 exhaust gas temperature sensor is dropped, replace it with a new one.


    1. Using a 14 mm union nut wrench, 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. Attach the sensor connector clamp.

  5. INSTALL NO. 3 EXHAUST GAS TEMPERATURE SENSOR

    Note

    If the No. 3 exhaust gas temperature sensor is dropped, replace it with a new one.


    1. A01ISIQE01
      Text in Illustration
      *1 White Tube
      *2 Protective Tube

      Temporarily install the No. 3 exhaust gas temperature sensor with the union nut.

    2. Attach the No. 3 exhaust gas temperature sensor connector clamp.

    3. Temporarily install the clamp with the nut.

      Note

      Make sure the clamp is aligned with the white tube of the wire harness as shown in the illustration.

    4. Tighten the nut.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

    5. Using a 14 mm union nut wrench, tighten the union nut of the No. 3 exhaust gas temperature sensor.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note


      • When tightening the union nut, make sure that the protective tube of the No. 3 exhaust gas temperature sensor is within the range shown in the illustration.

      • Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  6. INSTALL EXHAUST GAS TEMPERATURE SENSOR

    Note

    If the exhaust gas temperature sensor is dropped, replace it with a new one.


    1. Using a 14 mm union nut wrench, 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. Attach the exhaust gas temperature sensor connector clamp.

  7. INSTALL NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01ITTOE01
      Text in Illustration
      *1 Paint Mark (Pink)
      *a Front Side of Vehicle
      *b LH Side

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

      Tech Tips

      The direction of the hose clamp and paint mark is indicated in the illustration.

  8. INSTALL VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01ITVEE01
      Text in Illustration
      *1 Paint Mark (White)
      *a Front Side of Vehicle
      *b LH Side

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

      Tech Tips

      The direction of the hose clamp and paint mark is indicated in the illustration.

  9. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. A01IOL4E02

      Install a new gasket to the turbocharger sub-assembly.

      Text in Illustration
      A01ISM9 Top

      Tech Tips

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

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

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

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

    5. Temporarily install the manifold stay with the bolt and nut.

    6. A01IN6VE01

      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. A01IU0C

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

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }
    9. A01IQA2

      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.

    10. A01INQC

      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. A01INQW

      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.

    12. A01IPQW

      Tighten the nut of the manifold stay.

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

    13. Connect the 2 connectors.

  10. INSTALL MANIFOLD CONVERTOR INSULATOR SUB-ASSEMBLY


    1. Install the manifold converter insulator sub-assembly with the bolt.

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

      Note

      Make sure that the ceramic wool inside the manifold converter insulator sub-assembly does not fall out and is not bent.

  11. INSTALL NO. 4 MANIFOLD CONVERTER INSULATOR


    1. Install the No. 4 manifold converter insulator with the 4 bolts.

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

  12. INSTALL ENGINE ASSEMBLY

    Click here

  13. PERFORM CATALYST RECORD OF DPF THERMAL DETERIORATION CLEAR FUNCTION

    Click here