MONOLITHIC CONVERTER(w/o Glow Plug Controller) REMOVAL

PROCEDURE

  1. PRECAUTION

    Note:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notice before proceeding with work.

    Click here

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Click here

  3. REMOVE NO. 1 ENGINE COVER (w/ No. 1 Engine Cover)

    Click here

  4. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  5. REMOVE WATER GUARD PLATE LH (for LHD)

  6. REMOVE WATER GUARD PLATE LH (for RHD)

  7. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)

  8. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

  9. REMOVE OUTER COWL TOP PANEL (for LHD)

  10. REMOVE OUTER COWL TOP PANEL (for RHD)

  11. REMOVE BATTERY

    Click here

  12. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  13. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  14. REMOVE NO. 1 AIR TUBE

    Click here

  15. REMOVE FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

    Click here

  16. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    1. A295014

      Remove the 4 bolts and 4 compression springs.

    2. Remove the front exhaust pipe assembly from the 2 exhaust pipe supports.

    3. Remove the 2 gaskets from the front exhaust pipe assembly and No. 2 exhaust manifold converter sub-assembly.

  17. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR

    Click here

  18. REMOVE HARNESS BRACKET

    Click here

  19. REMOVE NO. 1 TURBO INSULATOR

    1. A296089C01

      *1

      Vacuum Transmitting Hose Assembly

      *2

      No. 2 Vacuum Transmitting Hose Assembly

      Slide the 2 clips and disconnect the vacuum transmitting hose assembly and No. 2 vacuum transmitting hose assembly remove the differential pressure sensor assembly.

    2. A200255

      Remove the 3 bolts and No. 1 turbo insulator.

  20. REMOVE AIR FUEL RATIO SENSOR

    Click here

  21. REMOVE NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY

    1. A199714

      Slide the clip and remove the No. 2 vacuum transmitting hose assembly from the No. 2 vacuum pipe.

  22. REMOVE VACUUM TRANSMITTING HOSE ASSEMBLY

    1. A199716

      Slide the clip and remove the vacuum transmitting hose assembly from the No. 1 vacuum pipe.

  23. REMOVE NO. 2 VACUUM PIPE

    1. A199704

      Remove the 2 bolts.

    2. Using a 14 mm union nut wrench, remove the No. 2 vacuum pipe.

  24. REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

    1. A199705

      Remove the 2 nuts and drive shaft heat insulator sub-assembly from the manifold support bracket.

  25. REMOVE NO. 4 MANIFOLD SUPPORT BRACKET

    1. A199706

      Remove the 3 bolts and No. 4 manifold support bracket from the No. 1 converter support bracket and No. 2 exhaust manifold converter sub-assembly.

  26. REMOVE NO. 3 MANIFOLD SUPPORT BRACKET

    1. A199707

      Remove the 3 bolts and No. 3 manifold support bracket from the No. 2 manifold support bracket and No. 2 exhaust manifold converter sub-assembly.

  27. REMOVE NO. 2 EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    1. A199708

      Remove the 2 nuts and No. 2 exhaust manifold converter sub-assembly from the exhaust manifold converter sub-assembly.

    2. Remove the gasket from the exhaust manifold converter sub-assembly.

  28. REMOVE NO. 1 VACUUM PIPE

    1. Remove the bolt.

    2. A199709

      Using a 14 mm union nut wrench, remove the No. 1 vacuum pipe from the exhaust manifold converter sub-assembly.

  29. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    1. A257964

      Disengage the 2 wire harness clamps from the wire harness bracket.

    2. A258513

      Remove the bolt and harness bracket.

    3. A199703C01

      *1

      Exhaust Gas Temperature Sensor Connector

      *2

      No. 2 Exhaust Gas Temperature Sensor Connector

      Disconnect the exhaust gas temperature sensor connector and No. 2 exhaust gas temperature sensor connector.

    4. Disengage the 2 wire harness clamps from the wire harness bracket and cylinder block side cover.

    5. A199752C01

      *1

      Exhaust Gas Temperature Sensor Connector

      *2

      No. 2 Exhaust Gas Temperature Sensor Connector

      Separate the exhaust gas temperature sensor connector and No. 2 exhaust gas temperature sensor connector from the wire harness bracket.

    6. Remove the bolt and wire harness bracket.

    7. A295027C01
      V100135

      Bolt
      V100136

      Nut

      Remove the bolt, 3 nuts and exhaust manifold converter sub-assembly.

    8. A193581

      Remove the gasket from the turbocharger sub-assembly.

  30. REMOVE EXHAUST GAS TEMPERATURE SENSOR

    Click here

  31. REMOVE NO. 2 EXHAUST GAS TEMPERATURE SENSOR

    Click here