MONOLITHIC CONVERTER INSTALLATION

Tech Tips

Perform "Inspection After Repair" after replacing the exhaust manifold converter sub-assembly Click here.


  1. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Tech Tips

    Perform "Inspection After Repair" after replacing the exhaust manifold converter sub-assembly Click here.


    1. A01IQG4

      Install the No. 2 manifold converter insulator with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    2. A01IODM

      Temporarily install the manifold stay with the 2 nuts.

    3. A01IUHBE01
      Text in Illustration
      *1 Turbocharger Sub-assembly
      *2 Gasket
      *3 V-band Clamp
      *4 Exhaust Manifold Converter Sub-assembly

      Temporarily install the exhaust manifold converter sub-assembly and engine bracket with the 3 nuts, 2 bolts, V-band clamp and new gasket.

    4. Tighten the engine bracket with the 2 bolts.

      Torque:
      21 N*m  { 218 kgf*cm, 16 ft.*lbf }
    5. A01INVE

      Temporarily install the manifold stay with the 2 bolts.

    6. A01IQWOE01
      Text in Illustration
      *1 V-band Clamp

      Align the V-band clamp as shown in the illustration and temporarily install it.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

      Tech Tips

      To prevent the V-band clamp from interfering with the No. 1 manifold converter insulator, temporarily install the V-band clamp at the angle shown in the illustration.

    7. Tighten the 5 nuts, 2 bolts, V-band clamp and exhaust manifold converter sub-assembly in the order shown in the illustration.

      A01IUDBE01
      Torque:
      for bolt
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }
      for nut
      21 N*m  { 218 kgf*cm, 16 ft.*lbf }
      for V-band clamp
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

  2. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 1 exhaust manifold heat insulator with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  3. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR


    1. Temporarily install the No. 1 manifold converter insulator with the 7 bolts and nut.

    2. A01IU8JE01

      Tighten the 7 bolts and nut in the order shown in the illustration.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  4. CONNECT NO. 1 VACUUM TRANSMITTING HOSE


    1. Connect the No. 1 vacuum transmitting hose to the exhaust manifold converter sub-assembly.

  5. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. Check the free length of the compression spring.


      1. A01IN16

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

        Minimum length
        41.5 mm (1.63 in.)

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

    2. A01IS8PE17
      Text in Illustration
      *1 Exhaust Manifold Converter Sub-assembly
      *2 Gasket
      *a Wooden Block

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

      Note


      • Be sure to install the gasket so that it faces the correct direction.

      • Do not reuse the gasket.

      • Do not damage the gasket.

      • When connecting the exhaust pipe, do not push in the gasket with the exhaust pipe.

    3. Install a new gasket to the front exhaust pipe assembly.

    4. Connect the front exhaust pipe assembly to the 3 exhaust pipe supports.

    5. Install the front exhaust pipe assembly with the 4 bolts and 4 compression springs.

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

  6. INSTALL FRONT FLOOR CENTER BRACE


    1. Install the front floor center brace with the 4 bolts.

      Torque:
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }

  7. INSTALL NO. 2 ENGINE UNDER COVER


    1. Install the No. 2 engine under cover with the 4 clips.

  8. INSTALL OUTER COWL TOP PANEL


    1. Install the outer cowl top panel with the 9 bolts.

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

  9. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY

    Click here

  10. INSTALL EXHAUST GAS TEMPERATURE SENSOR


  11. INSTALL AIR FUEL RATIO SENSOR

    Click here

  12. INSPECT FOR EXHAUST GAS LEAK

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

  13. PERFORM INITIALIZATION


    1. Perform DPF history information reset Click here.