MONOLITHIC CONVERTER(w/ Glow Plug Controller) INSTALLATION
CAUTION / NOTICE / HINT
After replacing the DPF catalytic converter, perform the "DPF Deterioration Record Clear" function using the GTS.
PROCEDURE
INSTALL NO. 2 EXHAUST GAS TEMPERATURE SENSOR
INSTALL NO. 1 VACUUM PIPE
Temporarily install the No. 1 vacuum pipe to the No. 2 exhaust manifold.
Connect the No. 1 vacuum pipe to the exhaust manifold with the bolt.
21 N*m
214 kgf*cm
15 ft.*lbf
-
*a
Torque Wrench Fulcrum Length
Using a 14 mm union nut wrench, tighten the No. 1 vacuum pipe.
Specified tightening torque
48 N*m
489 kgf*cm
35 ft.*lbf
Tip:Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
When using a 14 mm union nut wrench (fulcrum length of 25 mm (0.984 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 42 N*m (428 kgf*cm, 31 ft.*lbf)
INSTALL NO. 2 EXHAUST MANIFOLD
Install a new outlet turbine elbow gasket to the turbocharger sub-assembly.
-
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 exhaust manifold from falling.
-
*a
Torque Wrench Fulcrum Length
Temporarily install the No. 1 manifold support bracket to the cylinder block sub-assembly with the 3 bolts.
Using a 12 x 14 mm offset wrench and a 12 mm hexagon socket wrench, tighten the bolt A.
Specified tightening torque
37 N*m
377 kgf*cm
27 ft.*lbf
Tip:Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
When using a 12 x 14 mm offset wrench and a 12 mm hexagon socket wrench (fulcrum length of 206 mm (8.11 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 17 N*m (173 kgf*cm, 13 ft.*lbf)
Tighten the 2 bolts B.
37 N*m
377 kgf*cm
27 ft.*lbf
Temporarily install the No. 2 exhaust manifold to the turbocharger sub-assembly, No. 1 manifold support bracket, manifold stay and No. 2 manifold support bracket with the 4 bolts and 3 new nuts.
Tighten the 4 bolts and 3 nuts in the order shown in the illustration.
Bolt
37 N*m
377 kgf*cm
27 ft.*lbf
Nut
26 N*m
265 kgf*cm
19 ft.*lbf
INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY
Install the drive shaft heat insulator sub-assembly to the No. 1 manifold support bracket with the 2 nuts.
17.6 N*m
179 kgf*cm
13 ft.*lbf
INSTALL NO. 4 MANIFOLD SUPPORT BRACKET
-
Install the No. 4 manifold support bracket to the No. 2 exhaust manifold and No. 1 manifold support bracket with the 3 bolts in the order shown in the illustration.
37 N*m
377 kgf*cm
27 ft.*lbf
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INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
INSTALL NO. 5 MANIFOLD SUPPORT BRACKET
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Install the No. 5 manifold support bracket to the No. 2 exhaust manifold and cylinder block sub-assembly with the 2 bolts in the order shown in the illustration.
37 N*m
377 kgf*cm
27 ft.*lbf
-
INSTALL NO. 2 VACUUM PIPE
Temporarily install the No. 2 vacuum pipe to the No. 2 exhaust manifold.
Connect the No. 2 vacuum pipe to the manifold stay with the bolt.
21 N*m
214 kgf*cm
15 ft.*lbf
-
*a
Torque Wrench Fulcrum Length
Using a 14 mm union nut wrench, tighten the No. 2 vacuum pipe.
Specified tightening torque
30 N*m
306 kgf*cm
22 ft.*lbf
Tip:Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
When using a 14 mm union nut wrench (fulcrum length of 25 mm (0.984 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 26 N*m (265 kgf*cm, 19 ft.*lbf)
Connect the wire harness to the No. 2 vacuum pipe.
INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR
INSTALL FRONT EXHAUST PIPE ASSEMBLY
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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 the minimum, replace the compression spring.
Temporarily install 2 new gaskets to the front exhaust pipe assembly and No. 2 exhaust manifold.
-
*1
Front Exhaust Pipe Assembly or No. 2 Exhaust Manifold
*2
Gasket
*a
Wooden Block
Using a plastic hammer and wooden block, tap in the 2 gaskets until each surface is flush with the front exhaust pipe assembly and No. 2 exhaust manifold.
Note:Be sure to install the gaskets in the correct direction.
Do not reuse the gaskets.
Do not damage the gaskets.
Do not push in the gaskets by using the exhaust pipes when connecting them.
Connect the front exhaust pipe assembly to the 2 exhaust pipe supports.
Install the front exhaust pipe assembly to the No. 2 exhaust manifold with the 2 bolts and 2 compression springs.
43 N*m
438 kgf*cm
32 ft.*lbf
Tip:
*1
No. 2 Exhaust Manifold
*2
Front Exhaust Pipe Assembly
*3
Gasket
*a
Space between Flanges: 8.5 mm (0.335 in.)
After installation, check that the space between the flanges of the No. 2 exhaust manifold and front exhaust pipe assembly are consistent front-to-rear and left-to-right.
Install the front exhaust pipe assembly to the center exhaust pipe assembly with the 2 compression springs and 2 bolts.
43 N*m
438 kgf*cm
32 ft.*lbf
Tip:
*1
Front Exhaust Pipe Assembly
*2
Center Exhaust Pipe Assembly
*3
Gasket
*a
Space between Flanges: 6.5 mm (0.256 in.)
After installation, check that the space between the flanges of the front exhaust pipe assembly and center exhaust pipe assembly are consistent front-to-rear and left-to-right.
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INSTALL FRONT CENTER FLOOR BRACE SUB-ASSEMBLY
INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
INSTALL NO. 1 TURBO INSULATOR
Install the No. 1 turbo insulator to the turbocharger sub-assembly and No. 2 exhaust manifold with the 3 bolts.
7.0 N*m
71 kgf*cm
62 in.*lbf
Connect the wire harness to the No. 1 turbo insulator.
INSTALL NO. 1 AIR TUBE
INSTALL AIR CLEANER CASE SUB-ASSEMBLY
INSTALL AIR CLEANER CAP SUB-ASSEMBLY
INSTALL BATTERY
INSTALL NO. 2 HOSE TO HOSE TUBE (for LHD)
Connect the No. 2 hose to hose tube to the vehicle body with the 2 nuts.
5.4 N*m
55 kgf*cm
48 in.*lbf
Connect the check valve to connector tube hose to the No. 2 hose to hose tube and slide the clip to secure it.
INSTALL NO. 2 HOSE TO HOSE TUBE (for RHD)
Connect the No. 2 hose to hose tube to the vehicle body with the 2 nuts.
5.4 N*m
55 kgf*cm
48 in.*lbf
INSTALL SENSOR BRACKET
Install the sensor bracket to the cylinder head cover sub-assembly with the 2 bolts.
11 N*m
112 kgf*cm
8 ft.*lbf
INSTALL DIFFERENTIAL PRESSURE SENSOR
INSTALL EXHAUST GAS TEMPERATURE SENSOR
INSTALL AIR FUEL RATIO SENSOR
LEARNING DIFFERENTIAL PRESSURE SENSOR ASSEMBLY
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Note:When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
INSPECT FOR EXHAUST GAS LEAK