MONOLITHIC CONVERTER 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 notice 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 NO. 1 ENGINE COVER (w/ No. 1 Engine Cover)

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  4. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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  5. REMOVE WATER GUARD PLATE LH (for LHD)

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  6. REMOVE WATER GUARD PLATE LH (for RHD)

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  7. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)

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  8. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

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  9. REMOVE OUTER COWL TOP PANEL

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  10. REMOVE BATTERY

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  11. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

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  12. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

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  13. REMOVE NO. 1 AIR TUBE

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  14. REMOVE FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

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  15. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    1. A295014

      Remove the 4 bolts and 4 compression springs.

    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 converter sub-assembly.

  16. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR

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  17. REMOVE HARNESS BRACKET

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  18. REMOVE NO. 1 TURBO INSULATOR

    1. A296089C01

      *1

      Vacuum Transmitting Hose Assembly

      *2

      No. 2 Vacuum Transmitting Hose Assembly

      Slide the 2 clips and disconnect the vacuum transmitting hose assembly and No. 2 vacuum transmitting hose assembly remove the differential pressure sensor assembly.

    2. A200255

      Remove the 3 bolts and No. 1 turbo insulator.

  19. REMOVE AIR FUEL RATIO SENSOR

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  20. REMOVE NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY

    1. A199714

      Slide the clip and remove the No. 2 vacuum transmitting hose assembly from the No. 2 vacuum pipe.

  21. REMOVE VACUUM TRANSMITTING HOSE ASSEMBLY

    1. A199716

      Slide the clip and remove the vacuum transmitting hose assembly from the No. 1 vacuum pipe.

  22. REMOVE NO. 2 VACUUM PIPE

    1. A199704

      Remove the 2 bolts.

    2. Using a 14 mm union nut wrench, remove the No. 2 vacuum pipe.

  23. REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

    1. A199705

      Remove the 2 nuts and drive shaft heat insulator sub-assembly from the manifold support bracket.

  24. REMOVE NO. 4 MANIFOLD SUPPORT BRACKET

    1. A199706

      Remove the 3 bolts and No. 4 manifold support bracket from the No. 1 converter support bracket and No. 2 exhaust manifold converter sub-assembly.

  25. REMOVE NO. 3 MANIFOLD SUPPORT BRACKET

    1. A199707

      Remove the 3 bolts and No. 3 manifold support bracket from the No. 2 manifold support bracket and No. 2 exhaust manifold converter sub-assembly.

  26. REMOVE NO. 2 EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    1. A199708

      Remove the 2 nuts and No. 2 exhaust manifold converter sub-assembly from the exhaust manifold converter sub-assembly.

    2. Remove the gasket from the exhaust manifold converter sub-assembly.

  27. REMOVE NO. 1 VACUUM PIPE

    1. Remove the bolt.

    2. A199709

      Using a 14 mm union nut wrench, remove the No. 1 vacuum pipe from the exhaust manifold converter sub-assembly.

  28. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    1. A257964

      Disengage the 2 wire harness clamps from the wire harness bracket.

    2. A258513

      Remove the bolt and harness bracket.

    3. A199703C01

      *1

      Exhaust Gas Temperature Sensor Connector

      *2

      No. 2 Exhaust Gas Temperature Sensor Connector

      Disconnect the exhaust gas temperature sensor connector and No. 2 exhaust gas temperature sensor connector.

    4. Disengage the 2 wire harness clamps from the wire harness bracket and cylinder block side cover.

    5. A199752C01

      *1

      Exhaust Gas Temperature Sensor Connector

      *2

      No. 2 Exhaust Gas Temperature Sensor Connector

      Separate the exhaust gas temperature sensor connector and No. 2 exhaust gas temperature sensor connector from the wire harness bracket.

    6. Remove the bolt and wire harness bracket.

    7. A295027C01
      V100135

      Bolt
      V100136

      Nut

      Remove the bolt, 3 nuts and exhaust manifold converter sub-assembly.

    8. A193581

      Remove the gasket from the turbocharger sub-assembly.

  29. REMOVE EXHAUST GAS TEMPERATURE SENSOR

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  30. REMOVE NO. 2 EXHAUST GAS TEMPERATURE SENSOR

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