EXHAUST MANIFOLD CONVERTER INSTALLATION


  1. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. Set a new gasket and the exhaust manifold converter sub-assembly to the turbocharger sub-assembly.

    2. Temporarily install the exhaust pipe support stay to the cylinder block sub-assembly and exhaust manifold converter sub-assembly with the 3 bolts.

    3. B007VKRE02
      Text in Illustration
      *1 Exhaust Pipe Clamp
      *2 Exhaust Manifold Converter
      *3 Turbocharger Sub-assembly
      *4 Gasket

      Install a new exhaust pipe clamp to the exhaust manifold converter sub-assembly with a new nut.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    4. Tighten the 3 bolts and install the exhaust pipe support stay to the cylinder block sub-assembly and exhaust manifold converter sub-assembly.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  2. INSTALL NO. 2 EXHAUST PIPE SUPPORT STAY


    1. Install the No. 2 exhaust pipe support stay to the cylinder block sub-assembly and exhaust manifold converter sub-assembly with the bolt and 2 new nuts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  3. INSTALL NO. 1 TURBO INSULATOR


    1. Install the No. 1 turbo insulator to the exhaust manifold and turbocharger sub-assembly with the 3 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the 3 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  5. INSTALL AIR FUEL RATIO SENSOR

    Tech Tips

    Perform "Inspection After Repairs" after replacing the air fuel ratio sensor Click here.


    1. B007QX4E01
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      Using SST, install the air fuel ratio sensor to the front exhaust pipe.

      SST
      09224-00012
      Torque:
      Specified tightening torque
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

      Tech Tips


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

      • When using SST (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 38 N*m (384 kgf*cm, 28 ft.*lbf)

    2. Connect the connector.

  6. INSTALL ENGINE COVER BRACKET


    1. Install the engine cover bracket to the cylinder head sub-assembly with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    2. Connect the engine wire to the cylinder head sub-assembly with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  7. INSTALL PIPE CLAMP


    1. Install the pipe clamp to the engine cover bracket with the 3 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  8. TEMPORARILY INSTALL NO. 2 VACUUM PIPE


    1. Install a new clamp to the pipe clamp.

    2. Temporarily install the No. 2 vacuum pipe to the exhaust manifold converter sub-assembly.

  9. TEMPORARILY INSTALL NO. 1 VACUUM PIPE


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

    2. Install a new clamp to the No. 1 vacuum pipe and No. 2 vacuum pipe with the nut.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  10. TIGHTEN NO. 2 VACUUM PIPE


    1. B007TNSE01
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      Using a 17 mm union nut wrench, tighten the No. 2 vacuum pipe.

      Torque
      Specified tightening torque
      48 N*m {489 kgf*cm, 35 ft.*lbf}

      Tech Tips


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

      • When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 255 mm (10.0 in.)): 43 N*m (437 kgf*cm, 32 ft.*lbf)

  11. TIGHTEN NO. 1 VACUUM PIPE


    1. B007TNSE01
      Text in Illustration
      *a Torque Wrench Fulcrum Length

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

      Torque
      Specified tightening torque
      48 N*m {489 kgf*cm, 35 ft.*lbf}

      Tech Tips


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

      • When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 255 mm (10.0 in.)): 43 N*m (437 kgf*cm, 32 ft.*lbf)

  12. INSTALL EXHAUST GAS TEMPERATURE SENSOR


    1. B007TNSE06
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      Using a 14 mm union nut wrench, install the No. 3 exhaust gas temperature sensor to the exhaust manifold converter sub-assembly.

      Torque
      Specified tightening torque
      30 N*m {306 kgf*cm, 22 ft.*lbf}

      Note


      • If the No. 3 exhaust gas temperature sensor is dropped, replace it with a new.

      • When reusing the No. 3 exhaust gas temperature sensors, clean the screws and apply anti-seize compound before installing the No. 3 exhaust gas temperature sensor.

      Tech Tips


      • The connector color of the No. 3 exhaust gas temperature sensor is gray.

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

      • When using a union nut wrench (fulcrum length of 25 mm (0.984 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 26 N*m (268 kgf*cm, 19 ft.*lbf)

    2. B007TNSE06
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      Using a 14 mm union nut wrench, install the No. 2 exhaust gas temperature sensor to the exhaust manifold converter sub-assembly.

      Torque
      Specified tightening torque
      30 N*m {306 kgf*cm, 22 ft.*lbf}

      Note


      • If the No. 2 exhaust gas temperature sensor is dropped, replace it with a new.

      • When reusing the No. 2 exhaust gas temperature sensors, clean the screws and apply anti-seize compound before installing the No. 2 exhaust gas temperature sensor.

      Tech Tips


      • The connector color of the No. 2 exhaust gas temperature sensor is black.

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

      • When using a union nut wrench (fulcrum length of 25 mm (0.984 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 26 N*m (268 kgf*cm, 19 ft.*lbf)

    3. B007TNSE06
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      Using a 14 mm union nut wrench, install the exhaust gas temperature sensor to the exhaust manifold converter sub-assembly.

      Torque
      Specified tightening torque
      30 N*m {306 kgf*cm, 22 ft.*lbf}

      Note


      • If the exhaust gas temperature sensor is dropped, replace it with a new.

      • When reusing the exhaust gas temperature sensors, clean the screws and apply anti-seize compound before installing the exhaust gas temperature sensor.

      Tech Tips


      • The connector color of the exhaust gas temperature sensor is white.

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

      • When using a union nut wrench (fulcrum length of 25 mm (0.984 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 26 N*m (268 kgf*cm, 19 ft.*lbf)

    4. B007SBNE01
      Text in Illustration
      *a White
      *b Black
      *c Gray

      Attach the 3 colored connectors to the pipe clamp in the positions shown in the illustration.

    5. Close the clamp of the pipe clamp, and install the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note

      Arrange the exhaust gas temperature sensor wires so that they do not contact each other.

    6. Connect the No. 3 exhaust gas temperature sensor to the No. 1 vacuum pipe.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    7. Connect the 3 connectors to the 3 exhaust gas temperature sensors.

  13. INSTALL DIFFERENTIAL PRESSURE SENSOR


    1. B007VJOE01
      Text in Illustration
      *a Paint Mark

      Install the 2 air hoses to the differential pressure sensor, and slide the 2 clamps to secure the 2 hoses.

      Tech Tips

      Make sure the paint mark of the air hose side the differential pressure sensor.

    2. Connect the 2 air hoses to the No. 1 vacuum pipe and No. 2 vacuum pipe, and slide the 2 clamps to secure the 2 hoses.

    3. Install the differential pressure sensor to the pipe clamp with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    4. Connect the connector to the differential pressure sensor.

  14. INSTALL ENGINE ASSEMBLY

    Click here