MONOLITHIC CONVERTER(w/ Glow Plug Controller) REMOVAL

PROCEDURE

  1. PRECAUTION

    Note:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

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  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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  3. REMOVE AIR FUEL RATIO SENSOR

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  4. REMOVE EXHAUST GAS TEMPERATURE SENSOR

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  5. REMOVE DIFFERENTIAL PRESSURE SENSOR ASSEMBLY

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  6. REMOVE SENSOR BRACKET

    1. A349566

      Remove the 2 bolts and sensor bracket from the cylinder head cover sub-assembly.

  7. SEPARATE NO. 2 HOSE TO HOSE TUBE (for LHD)

    1. A354672

      Slide the clip and disconnect the check valve to connector tube hose from the No. 2 hose to hose tube.

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

  8. SEPARATE NO. 2 HOSE TO HOSE TUBE (for RHD)

    1. A354673

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

  9. REMOVE BATTERY

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  10. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

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  11. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

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  12. REMOVE NO. 1 AIR TUBE

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  13. REMOVE NO. 1 TURBO INSULATOR

    1. A359365

      Disconnect the wire harness from the No. 1 turbo insulator.

    2. A349569

      Remove the 3 bolts and No. 1 turbo insulator from the turbocharger sub-assembly and No. 2 exhaust manifold.

  14. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

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  15. REMOVE FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

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  16. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    1. A295014

      Remove the 4 bolts and 4 compression springs and disconnect the front exhaust pipe assembly from the center exhaust pipe assembly and No. 2 exhaust manifold.

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

    3. Remove the 2 gaskets from the front exhaust pipe assembly and No. 2 exhaust manifold.

  17. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR

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  18. REMOVE NO. 2 VACUUM PIPE

    1. A359366

      Disconnect the wire harness from the No. 2 vacuum pipe.

    2. A349579

      Remove the bolt to separate the No. 2 vacuum pipe from the manifold stay.

    3. Using a 14 mm union nut wrench, remove the No. 2 vacuum pipe from the No. 2 exhaust manifold.

  19. REMOVE NO. 5 MANIFOLD SUPPORT BRACKET

    1. A349572

      Remove the 2 bolts and No. 5 manifold support bracket from the No. 2 exhaust manifold and cylinder block sub-assembly.

  20. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

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  21. REMOVE NO. 4 MANIFOLD SUPPORT BRACKET

    1. A349573

      Remove the 3 bolts and No. 4 manifold support bracket from the No. 2 exhaust manifold and No. 1 manifold support bracket.

  22. REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

    1. A199705

      Remove the 2 nuts and drive shaft heat insulator sub-assembly from the No. 1 manifold support bracket.

  23. REMOVE NO. 2 EXHAUST MANIFOLD

    1. Remove the 4 bolts, 3 nuts and No. 2 exhaust manifold from the turbocharger sub-assembly, No. 1 manifold support bracket, manifold stay and No. 2 manifold support bracket.

      A359367
    2. A349576

      As shown in the illustration, secure the No. 2 exhaust manifold to the vehicle using a rope or similar.

      Note:

      Make sure to perform this step in order to prevent the No. 2 exhaust manifold from falling.

    3. A349577

      Remove the 3 bolts and No. 1 manifold support bracket from the cylinder block sub-assembly.

    4. Remove the No. 2 exhaust manifold.

    5. A349627

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

  24. REMOVE NO. 1 VACUUM PIPE

    1. A349578

      Remove the bolt to separate the No. 1 vacuum pipe from the No. 2 exhaust manifold.

    2. Using a 14 mm union nut wrench, remove the No. 1 vacuum pipe from the No. 2 exhaust manifold.

  25. REMOVE NO. 2 EXHAUST GAS TEMPERATURE SENSOR

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