MONOLITHIC CONVERTER INSTALLATION

CAUTION / NOTICE / HINT

PROCEDURE

1. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

   Tip:

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

   1. 

      Temporarily install the manifold stay with the 2 nuts.

   2. 

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

      Table 1. Text in Illustration

      *1	Turbocharger Sub-assembly
      *2	Gasket
      *3	V-band Clamp
      *4	Exhaust Manifold Converter Sub-assembly

   3. Tighten the engine bracket with the 3 bolts.

      19 N*m

      194 kgf*cm

      14 ft.*lbf

   4. 

      Temporarily install the manifold stay with the 2 bolts.

   5. 

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

      3.0 N*m

      31 kgf*cm

      27 in.*lbf

      Table 2. Text in Illustration

      *1	V-band Clamp

      Tip:

      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.

   6. 

      Tighten the V-band clamp.

      15 N*m

      153 kgf*cm

      11 ft.*lbf

      Table 3. Text in Illustration

      *1	V-band Clamp
      *a	Clearance

   7. Check the clearance of the V-band clamp.

      Note:

      Do not reuse a V-band clamp that has been tightened to the specified torque.

      Tip:

      After tightening the V-band clamp to the specified torque, check that the clearance is within 0 to 3.5 mm (0 to 0.138 in.). If the result is not as specified, reinstall the exhaust manifold converter sub-assembly as the installation position is incorrect.

   8. Tighten the 5 nuts, 2 bolts and exhaust manifold converter sub-assembly in the order shown in the illustration.

      

      for bolt

      38 N*m

      387 kgf*cm

      28 ft.*lbf

      for nut

      19 N*m

      194 kgf*cm

      14 ft.*lbf

2. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

   2. Attach the 2 clamps and connect the engine wire.

3. INSTALL FRONT EXHAUST PIPE ASSEMBLY

   1. Check the free length of the compression spring.

      1. 

         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. 

      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.

      Table 4. Text in Illustration

      *1	Exhaust Manifold Converter Sub-assembly
      *2	Gasket
      *a	Wooden Block

      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.

      43 N*m

      438 kgf*cm

      32 ft.*lbf

4. INSTALL FRONT FLOOR CENTER BRACE

   Click here

5. INSTALL NO. 2 ENGINE UNDER COVER

   Click here

6. INSTALL OUTER COWL TOP PANEL

   Click here

7. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY

   (Click here)

8. INSTALL HEATER WITH EXHAUST PIPE ASSEMBLY (w/ Combustion Type Power Heater)

   (Click here)

9. INSTALL DIFFERENTIAL PRESSURE SENSOR

   (Click here)

10. INSTALL EXHAUST GAS TEMPERATURE SENSOR

    • for Sensor 1: (Click here)

    • for Sensor 2: (Click here)

11. INSTALL AIR FUEL RATIO SENSOR

    • for Sensor 1: (Click here)

    • for Sensor 2: (Click here)

12. INSPECT FOR EXHAUST GAS LEAK

    Click here

13. PERFORM INITIALIZATION

    • Perform DPF history information reset (Click here).

    • Perform NOx storage catalyst learning value reset (Click here).