MONOLITHIC CONVERTER INSTALLATION

PROCEDURE

  1. INSTALL NO. 2 MANIFOLD CONVERTER INSULATOR

    1. Install the No. 2 manifold converter insulator with the 3 bolts.

      29 N*m

      291 kgf*cm

      21 ft.*lbf

  2. INSTALL NO. 2 VACUUM PIPE

    1. Temporarily install the No. 2 vacuum pipe with the union nut and bolt.

    2. Tighten the bolt.

      25 N*m

      255 kgf*cm

      18 ft.*lbf

    3. Using a 14 mm union nut wrench, tighten the union nut of the No. 2 vacuum pipe.

      30 N*m

      306 kgf*cm

      22 ft.*lbf

      Note:

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench.

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  3. INSTALL NO. 1 VACUUM PIPE

    1. Temporarily install the No. 1 vacuum pipe with the union nut and bolt.

    2. Tighten the bolt.

      25 N*m

      255 kgf*cm

      18 ft.*lbf

    3. Using a 17 mm union nut wrench, tighten the union nut of the No. 1 vacuum pipe.

      48 N*m

      489 kgf*cm

      35 ft.*lbf

      Note:

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench.

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  4. INSTALL NO. 2 EXHAUST GAS TEMPERATURE SENSOR

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  5. INSTALL NO. 3 EXHAUST GAS TEMPERATURE SENSOR

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  6. INSTALL EXHAUST GAS TEMPERATURE SENSOR

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  7. INSTALL NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY

    1. A273002C01

      *1

      Paint Mark (Green)

      *a

      Front Side of Vehicle

      *b

      LH Side

      Install the No. 2 vacuum transmitting hose assembly to the No. 2 vacuum pipe, and slide the clamp to secure the hose.

      Tip:

      The direction of the vacuum transmitting hose clamp is indicated in the illustration.

  8. INSTALL VACUUM TRANSMITTING HOSE ASSEMBLY

    1. A273001C01

      *1

      Paint Mark (Light Blue)

      *a

      Front Side of Vehicle

      *b

      LH Side

      Install the vacuum transmitting hose assembly to the No. 1 vacuum pipe, and slide the clamp to secure the hose.

      Tip:

      The direction of the vacuum transmitting hose clamp is indicated in the illustration.

  9. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    1. A197499C02
      V100135

      Top

      Install a new gasket to the turbocharger sub-assembly.

      Tip:

      Make sure that the part labeled A is facing downwards as shown in the illustration.

    2. Temporarily install the exhaust manifold converter sub-assembly with 3 new nuts.

    3. Temporarily install the No. 2 exhaust manifold stay with the 2 bolts and nut.

    4. Temporarily install the No. 2 manifold stay with the 3 bolts.

    5. Temporarily install the manifold stay with the bolt and nut.

    6. A273038N01

      Tighten the 2 bolts of the No. 2 exhaust manifold stay in the order shown in the illustration.

      56 N*m

      571 kgf*cm

      41 ft.*lbf

    7. Tighten the 3 nuts of the exhaust manifold converter sub-assembly.

      25 N*m

      255 kgf*cm

      18 ft.*lbf

      Note:

      Tighten the nuts while pressing the exhaust manifold converter sub-assembly against the engine.

    8. A201849

      Tighten the nut of the No. 2 exhaust manifold stay.

      56 N*m

      571 kgf*cm

      41 ft.*lbf

    9. A201845

      Tighten the bolt of the No. 2 manifold stay shown in the illustration.

      56 N*m

      571 kgf*cm

      41 ft.*lbf

      Note:

      Tighten the bolt while pressing the No. 2 manifold stay against the exhaust manifold converter sub-assembly and cylinder block sub-assembly.

    10. A201846

      Tighten the 2 bolts of the No. 2 manifold stay shown in the illustration.

      56 N*m

      571 kgf*cm

      41 ft.*lbf

    11. A201850

      Tighten the bolt of the manifold stay.

      25 N*m

      255 kgf*cm

      18 ft.*lbf

      Note:

      Tighten the bolt while pressing the manifold stay against the exhaust manifold converter sub-assembly and cylinder block sub-assembly.

    12. A201851

      Tighten the nut of the manifold stay.

      25 N*m

      255 kgf*cm

      18 ft.*lbf

    13. Connect the No. 2 exhaust gas temperature sensor connector and No. 3 exhaust gas temperature sensor connector.

  10. INSTALL MANIFOLD CONVERTER INSULATOR SUB-ASSEMBLY

    1. Install the manifold converter insulator sub-assembly with the bolt.

      29 N*m

      291 kgf*cm

      21 ft.*lbf

      Note:

      Make sure that the ceramic wool inside the manifold converter insulator sub-assembly does not fall out and is not bent.

  11. INSTALL NO. 4 MANIFOLD CONVERTER INSULATOR

    1. Install the No. 4 manifold converter insulator with the 4 bolts.

      29 N*m

      291 kgf*cm

      21 ft.*lbf

  12. INSTALL ENGINE ASSEMBLY

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  13. PERFORM CATALYST RECORD OF DPF THERMAL DETERIORATION CLEAR FUNCTION

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