MONOLITHIC CONVERTER INSTALLATION

PROCEDURE

  1. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    1. A341668

      Temporarily install the manifold stay with the 2 nuts.

    2. A341669C01

      *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. A341670

      Temporarily install the manifold stay with the 2 bolts.

    5. A341671C01

      *1

      V-band Clamp

      *a

      20°

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

      2.0 N*m

      20 kgf*cm

      18 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. Tighten the 5 nuts, 2 bolts, V-band clamp and exhaust manifold converter sub-assembly in the order shown in the illustration.

      A361093N01

      for Bolt

      38 N*m

      387 kgf*cm

      28 ft.*lbf

      for Nut

      19 N*m

      194 kgf*cm

      14 ft.*lbf

      for V-band clamp

      15 N*m

      153 kgf*cm

      11 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. A128853

      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. A181728C95

      *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. A258941C17

      *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 FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

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  5. INSTALL OUTER COWL TOP PANEL

  6. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY

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  7. INSTALL DIFFERENTIAL PRESSURE SENSOR

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  8. INSTALL EXHAUST GAS TEMPERATURE SENSOR

  9. INSTALL AIR FUEL RATIO SENSOR

  10. INSPECT FOR EXHAUST GAS LEAK

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

  11. PERFORM INITIALIZATION

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