MONOLITHIC CONVERTER INSTALLATION

PROCEDURE

1. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

   1. 

      Temporarily install the manifold stay with the 2 nuts.

   2. 

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

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

   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. 

      *1	V-band Clamp

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

      3.0 N*m

      31 kgf*cm

      27 in.*lbf

      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. 

      *1	V-band Clamp
      *a	Clearance

      Tighten the V-band clamp.

      15 N*m

      153 kgf*cm

      11 ft.*lbf

   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. 

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

      Minimum Free Length (front)	41.5 mm (1.63 in.)
      Minimum Free Length (rear)	38.5 mm (1.52 in.)

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

   2. 

      *1	Exhaust Manifold Converter Sub-assembly and Front Exhaust Pipe Assembly
      *2	Gasket
      *a	Wooden Block

      Using a plastic hammer and wooden block, tap in 2 new gaskets until its surface is flush with the exhaust manifold converter sub-assembly and front exhaust pipe sub-assembly.

      Note:

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

      • Do not reuse the gasket.

      • Do not damage the gasket.

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

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

   4. 

      *1	Exhaust Manifold Converter Sub-assembly or Front Exhaust Pipe Assembly
      *2	Front Exhaust Pipe Assembly or tail exhaust pipe assembly
      *3	Gasket
      *a	Space between Flanges: 8.5 mm (0.335 in.)

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

      43 N*m

      438 kgf*cm

      32 ft.*lbf

      Tip:

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

4. INSTALL NO. 2 ENGINE UNDER COVER

   Click hereClick here

5. INSTALL NO. 1 FUEL TANK PROTECTOR

   Click here

6. INSTALL FRONT FLOOR COVER

   Click here

7. INSTALL NO. 1 ENGINE UNDER COVER

   Click hereClick here

8. INSTALL HEATER AND ACCESSORY ASSEMBLY (w/ Combustion Type Power Heater)

   Click here

9. INSTALL OUTER COWL TOP PANEL

   1. Install the outer cowl top panel sub-assembly with the 13 bolts.

      7.0 N*m

      71 kgf*cm

      62 in.*lbf

   2. Attach the clamp to the outer cowl top panel sub-assembly.

10. INSTALL NO. 3 COWL TOP PANEL INSULATOR

    1. Install the No. 3 cowl top panel insulator with the 4 nuts.

       5.5 N*m

       56 kgf*cm

       49 in.*lbf

11. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY

    Click here

12. INSTALL DIFFERENTIAL PRESSURE SENSOR

    Click here

13. INSTALL EXHAUST GAS TEMPERATURE SENSOR

    • for Sensor 1:

      Click here

    • for Sensor 2:

      Click here

14. INSTALL AIR FUEL RATIO SENSOR

    • for Sensor 1:

      Click here

    • for Sensor 2:

      Click here

15. INSPECT FOR EXHAUST GAS LEAK

    1. If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

16. PERFORM INITIALIZATION

    Click here