MONOLITHIC CONVERTER REMOVAL

PROCEDURE

  1. REMOVE INTERCOOLER ASSEMBLY

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  2. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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  3. REMOVE WATER GUARD PLATE LH (for LHD)

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  4. REMOVE WATER GUARD PLATE LH (for RHD)

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

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

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  7. REMOVE OUTER COWL TOP PANEL (for LHD)

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  8. REMOVE OUTER COWL TOP PANEL (for RHD)

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  9. REMOVE AIR FUEL RATIO SENSOR

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  10. REMOVE NO. 1 HOSE TO HOSE TUBE

    1. A426695C01

      *A

      for LHD

      *B

      for RHD

      Slide the clip and disconnect the check valve to connector tube hose from the No. 1 hose to hose tube.

    2. Slide the clip and disconnect the union to connector tube hose from the No. 1 hose to hose tube.

    3. A426696C01

      *A

      for LHD

      *B

      for RHD

      Remove the 2 nuts and No. 1 hose to hose tube from the vehicle body.

  11. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

    1. A353504C02

      *a

      Air Cleaner Cap Sub-assembly Clamp

      *b

      Guide

      Disconnect the intake mass air flow meter sub-assembly connector.

    2. Disengage the wire harness from the air cleaner cap sub-assembly.

    3. Disengage the 2 air cleaner cap sub-assembly clamps.

    4. Disengage the 2 guides to separate the air cleaner cap sub-assembly from the air cleaner case sub-assembly.

    5. Loosen the hose clamp and remove the air cleaner cap with air cleaner hose from the inlet No. 1 air duct sub-assembly.

  12. REMOVE ENGINE WIRE

    1. A426697C01
      V100135

      Bolt
      V100136

      Nut
      V100137

      Connector

      Disconnect the 7 connectors.

    2. Remove the bolt and nut.

    3. Disengage the 3 wire harness clamps.

    4. A353511

      Remove the 2 bolts and wire harness clamp bracket from the cylinder head sub-assembly.

  13. REMOVE VENTILATION HOSE

    1. A426698C01

      *1

      Ventilation Hose

      *2

      No. 4 Ventilation Hose

      Slide the 2 clips and remove the ventilation hose from the cylinder head cover sub-assembly and inlet No. 1 air duct sub-assembly.

    2. Slide the 2 clips and remove the No. 4 ventilation hose from the ventilation ejector and inlet No. 1 air duct sub-assembly.

  14. REMOVE VENTILATION EJECTOR

    1. A426699

      Remove the 2 bolts and ventilation ejector from the cylinder head cover sub-assembly.

    2. Remove the O-ring from the cylinder head cover sub-assembly.

  15. REMOVE DIFFERENTIAL PRESSURE SENSOR

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  16. REMOVE NO. 1 PIPE

    1. A426700

      Remove the nut and disconnect the No. 1 pipe from the exhaust manifold converter sub-assembly.

    2. Using a 14 mm union nut wrench, disconnect the nut of No. 1 pipe and remove the No. 1 pipe.

  17. REMOVE AIR TUBE ASSEMBLY

    1. A353514C02

      *1

      No. 2 Intercooler Water Hose

      *2

      No. 3 Intercooler Water Hose

      Slide the clip and disconnect the No. 2 intercooler water hose and No. 3 intercooler water hose from the turbocharger sub-assembly.

    2. A353515C02

      *1

      No. 2 Intercooler Water Hose

      *2

      No. 3 Intercooler Water Hose

      Disconnect the No. 2 intercooler water hose and No. 3 intercooler water hose from the No. 1 water hose clamp bracket.

    3. A353516

      Loosen the hose clamp and remove the air tube assembly from the turbocharger sub-assembly.

    4. A426703

      Remove the bolt and air tube assembly from the cylinder head cover sub-assembly.

  18. REMOVE VACUUM REGULATING VALVE ASSEMBLY

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  19. REMOVE NO. 2 VACUUM SWITCHING VALVE BRACKET

    1. A426704

      Remove the 2 bolts and No. 2 vacuum switching valve bracket from the cylinder head sub-assembly.

  20. REMOVE INLET NO. 1 AIR DUCT SUB-ASSEMBLY

    1. A426705

      Disconnect the No. 1 vacuum transmitting hose assembly from the vacuum tank.

    2. A426706

      Remove the 2 bolts and vacuum tank from the inlet No. 1 air duct sub-assembly.

    3. A426707

      Disconnect the No. 1 vacuum transmitting hose assembly from the vacuum pump assembly.

    4. A426702

      Disengage the wire harness clamp from the inlet No. 1 air duct sub-assembly.

    5. A427508

      Remove the bolt and disconnect the inlet No. 1 air duct sub-assembly from the fuel pump protector.

    6. A353521C02

      *1

      No. 2 Vacuum Transmitting Hose Assembly

      *2

      Inlet No. 1 Air Duct Sub-assembly

      Disconnect the No. 2 vacuum transmitting hose assembly from the turbocharger sub-assembly.

    7. Loosen the hose clamp and remove the inlet No. 1 air duct sub-assembly from the turbocharger sub-assembly.

  21. REMOVE NO. 1 ENGINE COVER

    1. A353524

      Remove the No. 1 engine cover from the cylinder head cover sub-assembly and cylinder head sub-assembly.

  22. REMOVE FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

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  23. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    1. A389621

      Disconnect the heated oxygen sensor connector.

    2. Disengage the wire harness clamp.

    3. A427509

      Remove the 4 bolts and 4 compression springs and disconnect the front exhaust pipe assembly from the exhaust manifold converter sub-assembly and tail exhaust pipe assembly.

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

    5. Remove the 2 exhaust pipe gaskets from the exhaust manifold converter sub-assembly and tail exhaust pipe assembly.

  24. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR

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  25. REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

    1. A427510

      Remove the bolt, nut and drive shaft heat insulator sub-assembly from the cylinder block sub-assembly and manifold support bracket.

  26. REMOVE MANIFOLD SUPPORT BRACKET

    1. A427511

      Remove the 3 bolts and manifold support bracket from the cylinder block sub-assembly and exhaust manifold converter sub-assembly.

  27. REMOVE NO. 2 TURBO INSULATOR

    1. A427512

      Remove the 2 bolts and No. 2 turbo insulator from the cylinder head sub-assembly and heat insulator bracket.

  28. REMOVE NO. 1 MANIFOLD CONVERTER INSULATOR

    1. A427513

      Remove the 3 bolts and No. 1 manifold converter insulator from the exhaust manifold converter sub-assembly.

  29. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    1. A427514

      Remove the 4 nuts and exhaust manifold converter sub-assembly from the turbocharger sub-assembly.

  30. REMOVE OUTLET TURBINE ELBOW GASKET

    1. A351371

      Remove the outlet turbine elbow gasket from the turbocharger sub-assembly.