MONOLITHIC CONVERTER INSTALLATION

PROCEDURE

  1. INSTALL OUTLET TURBINE ELBOW GASKET

    1. Install a new outlet turbine elbow gasket to the turbocharger sub-assembly.

  2. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    1. Temporarily install the exhaust manifold converter sub-assembly to the turbocharger sub-assembly with 4 new nuts.

    2. A427514N01

      Tighten the 4 nuts in the order shown in the illustration.

      40 N*m

      408 kgf*cm

      30 ft.*lbf

  3. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR

    1. Temporarily install the No. 1 manifold converter insulator to the exhaust manifold converter sub-assembly with the 3 bolts.

    2. A427513N01

      Tighten the 3 bolts in the order shown in the illustration.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  4. INSTALL NO. 2 TURBO INSULATOR

    1. Temporarily install the No. 2 turbo insulator to the cylinder head sub-assembly and heat insulator bracket with the 2 bolts.

    2. A427512C01

      Tighten the 2 bolts in the order shown in the illustration.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  5. INSTALL MANIFOLD SUPPORT BRACKET

    1. Install the manifold support bracket to the cylinder block sub-assembly and exhaust manifold converter sub-assembly with the 3 bolts.

      40 N*m

      408 kgf*cm

      30 ft.*lbf

  6. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

    1. Temporarily install the drive shaft heat insulator sub-assembly to the cylinder block sub-assembly and manifold support bracket with the bolt and nut.

    2. A427510N01

      Tighten the bolt and nut in the order shown in the illustration.

      17.6 N*m

      179 kgf*cm

      13 ft.*lbf

  7. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR

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  8. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    1. A128853

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

      Standard Length

      Front Side

      43 mm (1.69 in.)

      Rear Side

      40 mm (1.57 in.)

      Minimum Free Length

      Front Side

      41.5 mm (1.63 in.)

      Rear Side

      38.5 mm (1.52 in.)

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

    2. Temporarily install 2 new exhaust pipe gasket to the exhaust manifold converter sub-assembly and front exhaust pipe assembly.

    3. A181728C96

      *1

      Exhaust Manifold Converter Sub-assembly or Front Exhaust Pipe Assembly

      *2

      Exhaust Pipe Gasket

      *a

      Wooden Block

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

      Note:

      • Be sure to install the exhaust pipe gasket in the correct direction.

      • Do not reuse the exhaust pipe gasket.

      • Do not damage the exhaust pipe gasket.

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

    4. Connect the front exhaust pipe assembly to the 2 exhaust pipe supports.

    5. Install the front exhaust pipe assembly to the exhaust manifold converter sub-assembly and tail exhaust pipe assembly with the 4 compression springs and 4 bolts.

      43 N*m

      438 kgf*cm

      32 ft.*lbf

      A258941C38

      *1

      Exhaust Manifold Converter Sub-assembly or Front Exhaust Pipe Assembly

      *2

      Front Exhaust Pipe Assembly or Tail Exhaust Pipe Assembly

      *3

      Exhaust Pipe Gasket

      *a

      Space between Flanges:

      - Front Side: 8.5 mm (0.335 in.)

      - Rear Side: 6.5 mm (0.256 in.)
      Tip:

      • After installation, check that the space between the flanges of the exhaust manifold converter sub-assembly and front exhaust pipe assembly is consistent front-to-rear and left-to-right.

      • After installation, check that the space between the flanges of the front exhaust pipe assembly and tail exhaust pipe assembly is consistent front-to-rear and left-to-right.

    6. Engage the 2 wire harness clamps.

    7. Connect the heated oxygen sensor connector.

  9. INSTALL FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

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  10. INSTALL NO. 1 ENGINE COVER

    1. Install the No. 1 engine cover to the cylinder head cover sub-assembly and cylinder head sub-assembly.

  11. INSTALL INLET NO. 1 AIR DUCT SUB-ASSEMBLY

    1. Connect the inlet No. 1 air duct sub-assembly to the turbocharger sub-assembly.

    2. Tighten the hose clamp.

      4.0 N*m

      41 kgf*cm

      35 in.*lbf

    3. Connect the No. 2 vacuum transmitting hose assembly to the turbocharger sub-assembly.

    4. Connect the inlet No. 1 air duct sub-assembly to the fuel pump protector with the bolt.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

    5. Connect the No. 1 vacuum transmitting hose assembly to the vacuum pump assembly.

    6. Install the vacuum tank to the inlet No. 1 air duct sub-assembly with the 2 bolts.

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

    7. Connect the No. 1 vacuum transmitting hose assembly to the vacuum tank.

  12. INSTALL NO. 2 VACUUM SWITCHING VALVE BRACKET

    1. Install the No. 2 vacuum switching valve bracket to the cylinder head sub-assembly with the 2 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  13. INSTALL VACUUM REGULATING VALVE ASSEMBLY

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  14. INSTALL AIR TUBE ASSEMBLY

    1. Install the air tube assembly to the cylinder head cover sub-assembly with the bolt.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

    2. Connect the air tube assembly to the turbocharger sub-assembly.

    3. Tighten the hose clamp.

      6.3 N*m

      64 kgf*cm

      56 in.*lbf

    4. Connect the No. 2 intercooler water hose and No. 3 intercooler water hose to the No. 1 water hose clamp bracket.

    5. Connect the No. 2 intercooler water hose and No. 3 intercooler water hose to the turbocharger sub-assembly and slide the 2 clips to secure them.

  15. INSTALL NO. 1 PIPE

    1. Temporarily install the No. 1 pipe to the exhaust manifold converter sub-assembly.

    2. A426701C01

      *a

      Torque Wrench Fulcrum Length

      Using a 14 mm union nut wrench, tighten the flange nut of the No. 1 pipe.

      Specified tightening torque

      30 N*m

      306 kgf*cm

      22 ft.*lbf

      Tip:

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a 14 mm union nut wrench (fulcrum length of 25 mm (0.984 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 26.3 N*m (268 kgf*cm, 19 ft.*lbf)

    3. Tighten the nut.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  16. INSTALL DIFFERENTIAL PRESSURE SENSOR

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  17. INSTALL VENTILATION EJECTOR

    1. Apply a light coat of engine oil to the O-ring.

      Note:

      When reusing the ventilation ejector, inspect the O-ring.

    2. Install the O-ring to the cylinder head cover sub-assembly.

    3. Install the ventilation ejector to the cylinder head cover sub-assembly with the 2 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  18. INSTALL VENTILATION HOSE

    1. Install the ventilation hose to the cylinder head cover sub-assembly and inlet No. 1 air duct sub-assembly and slide the 2 clips to secure them.

    2. Install the No. 4 ventilation hose to the ventilation ejector and inlet No. 1 air duct sub-assembly and slide the 2 clips to secure them.

  19. INSTALL ENGINE WIRE

    1. Using a 10 mm deep socket wrench, install the wire harness clamp bracket to the cylinder head sub-assembly with the 2 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

    2. A426697C01
      V100135

      Bolt
      V100136

      Nut
      V100137

      Connector

      Engage the 3 wire harness clamps.

    3. Install the bolt and nut.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

    4. Connect the 7 connectors.

  20. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

    1. A353505C02

      *a

      Air Cleaner Cap Sub-assembly Clamp

      *b

      Guide

      *c

      Upper

      *d

      RH

      *e

      Stopper

      *f

      Protrusion

      *g

      Cutout

      Connect the air cleaner cap with air cleaner hose to the inlet No. 1 air duct sub-assembly.

      Note:

      Align the cutout of the air cleaner hose assembly with the protrusion of the inlet No. 1 air duct sub-assembly.

    2. Tighten the hose clamp in the position shown in the illustration.

      2.0 N*m

      20 kgf*cm

      18 in.*lbf

    3. Engage the 2 guides to install the air cleaner cap sub-assembly to the air cleaner case sub-assembly.

    4. Engage the 2 air cleaner cap sub-assembly clamps to install the air cleaner cap sub-assembly.

    5. Engage the wire harness to the air cleaner cap sub-assembly.

    6. Connect the intake mass air flow meter sub-assembly connector.

  21. INSTALL NO. 1 HOSE TO HOSE TUBE

    1. Install the No. 1 hose to hose tube to the vehicle body with the 2 nuts.

      5.4 N*m

      55 kgf*cm

      48 in.*lbf

    2. Connect the union to connector tube hose to the No. 1 hose to hose tube and slide the clip to secure it.

    3. Connect the check valve to connector tube hose to the No. 1 hose to hose tube and slide the clip to secure it.

  22. INSTALL AIR FUEL RATIO SENSOR

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  23. INSTALL OUTER COWL TOP PANEL (for LHD)

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  24. INSTALL OUTER COWL TOP PANEL (for RHD)

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  25. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)

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  26. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

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  27. INSTALL WATER GUARD PLATE LH (for LHD)

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  28. INSTALL WATER GUARD PLATE LH (for RHD)

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  29. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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  30. INSTALL INTERCOOLER ASSEMBLY

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  31. INSPECT FOR EXHAUST GAS LEAK

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