EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

id0115z7800200

Replacement Part (Fuel injector (2pin type))

Gasket
 
Quantity: 1
 
Location of use: Main silencer
Nut
 
Quantity: 4
 
Location of use: Middle pipe
Gasket
 
Quantity: 1
 
Location of use: Middle pipe
Gasket
 
Quantity: 3
 
Location of use: Catalytic converter
Washer
 
Quantity: 1
 
Location of use: Catalytic converter
Exhaust gas pressure hose
 
Quantity: 2
 
Location of use: Catalytic converter
Clip
 
Quantity: 2
 
Location of use: Catalytic converter
—
—

Replacement Part (Fuel injector (6pin type))

Gasket
 
Quantity: 1
 
Location of use: Main silencer
Nut
 
Quantity: 4
 
Location of use: Middle pipe
Gasket
 
Quantity: 1
 
Location of use: Middle pipe
Gasket
 
Quantity: 3
 
Location of use: Catalytic converter
Washer
 
Quantity: 2
 
Location of use: Catalytic converter
Gasket
 
Quantity: 1
 
Location of use: Exhaust manifold
Nut
 
Quantity: 10
 
Location of use: Exhaust manifold
Stud
 
Quantity: 10
 
Location of use: Exhaust manifold
Exhaust gas pressure hose
 
Quantity: 2
 
Location of use: Catalytic converter
Clip
 
Quantity: 2
 
Location of use: Catalytic converter
—
—

Warning
•  A hot engine and exhaust system can cause severe burns. Turn off the engine and wait until they are cool before removing the exhaust system.
Caution
•  Perform exhaust gas temperature sensor removal/installation only when inspection or replacement is required, such as when DTCs for the sensor are displayed, because it may cause exhaust gas leakage. If the exhaust gas temperature sensor is removed/installed once, always verify that there is no exhaust gas leakage after reinstallation.
Note
•  If the catalytic converter is replaced, perform the “Operation After Replacing Catalytic Converter” procedure.

Operation After Replacing Catalytic Converter

1.  If the catalytic converter is replaced, perform the following procedure.

STEP

ACTION

PAGE/CONDITION
1
Perform diesel particulate filter data reset procedure.
(See DIESEL PARTICULATE FILTER DATA RESET [SKYACTIV-D 2.2].)
2
Switch the ignition off.
—
3
Wait for 20 s. (Fuel injector (2pin type))
Wait for 30 s. (Fuel injector (6pin type))
—
4
Switch the ignition ON (engine off).
—
5
Perform KOEO self-test procedure.
(See KOEO/KOER SELF TEST [PCM (SKYACTIV-D 2.2)].)
6
Perform KOER self-test procedure.
(See KOEO/KOER SELF TEST [PCM (SKYACTIV-D 2.2)].)
7
Perform fuel injector injection amount correction.
(See FUEL INJECTOR INJECTION AMOUNT CORRECTION [SKYACTIV-D 2.2].)
8
Perform compulsory diesel particulate filter regeneration.
(See COMPULSORY DIESEL PARTICULATE FILTER REGENERATION [SKYACTIV-D 2.2].)
9
Clear the DTCs.
(See OBD READ/CLEAR DIAGNOSTIC TEST RESULTS [PCM (SKYACTIV-D 2.2)].)


Exhaust System Removal/Installation (2WD) (Fuel injector (2pin type))

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove in the order shown in the figure.

3.  Remove the exhaust system insulator. (See Exhaust system insulator removal/installation (2WD) (Fuel injector (2pin type)).)

4.  Install in the reverse order of removal.

Step 1

ac5wzw00005796

1
Main silencer
2
Plate
3
Brace bar
(See Brace bar removal note (2WD) (Fuel injector (2pin type)).)
4
Tunnel member
5
Middle pipe

Step 2

ac5wzw00014360

1
Insulator
(See Insulator removal note (2WD) (Fuel injector (2pin type)).)
2
Catalytic converter insulator
(See Catalytic converter insulator installation note (2WD) (Fuel injector (2pin type)).)
3
Exhaust gas pressure hose
4
Catalytic converter upper bracket
(See Catalytic converter bracket installation note (2WD) (Fuel injector (2pin type)).)
5
Catalytic converter lower bracket
(See Catalytic converter lower bracket removal note (2WD) (Fuel injector (2pin type)).)
(See Catalytic converter bracket installation note (2WD) (Fuel injector (2pin type)).)
6
Catalytic converter
(See Catalytic converter removal note (2WD) (Fuel injector (2pin type)).)
(See Catalytic converter installation note (2WD) (Fuel injector (2pin type)).)
(See Operation After Replacing Catalytic Converter.)


Exhaust system insulator removal/installation (2WD) (Fuel injector (2pin type))

1.  Remove in the order shown in the figure.

2.  Install in the reverse order of removal.

ac5wzw00013596

1
Insulator (rear)
(See Insulator (rear) removal note (2WD) (Fuel injector (2pin type)).)
2
Insulator (middle)
3
Insulator (front)


Insulator (rear) removal note (2WD) (Fuel injector (2pin type))

Note
•  If re-installed, use the same rivets.

1.  Using a hammer and punch (diam. 2—2.8 mm{0.08—0.11 in}), punch out the mandrel.

ac5wzw00005799

2.  Pull out and remove the flange using a drill (diam. 5 mm{0.2 in}).

ac5wzw00005800


Brace bar removal note (2WD) (Fuel injector (2pin type))

1.  Remove the floor and cover. (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

2.  Remove the brace bar.


Insulator removal note (2WD) (Fuel injector (2pin type))

1.  Remove the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

2.  Remove the cowl grille (See COWL GRILLE REMOVAL/INSTALLATION.).

3.  Remove the windshield wiper motor and link. (See WINDSHIELD WIPER MOTOR AND LINK REMOVAL/INSTALLATION.)

4.  Remove the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION.)

5.  Remove the insulator.


Catalytic converter lower bracket removal note (2WD) (Fuel injector (2pin type))

1.  Remove the front crossmember. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

2.  Remove the catalytic converter lower bracket.


Catalytic converter removal note (2WD) (Fuel injector (2pin type))

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

2.  Disconnect the exhaust gas temperature sensor No.3 connector.

3.  Remove the exhaust gas temperature sensor No.3 wiring harness installation nuts. (See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

4.  Disconnect the A/F sensor connector.

5.  Remove the catalytic converter.


Catalytic converter installation note (2WD) (Fuel injector (2pin type))

1.  Temporarily tighten bolt and nuts shown in the figure.

ac5wzw00005801

2.  Tighten the bolt and nuts in the other shown in the figure.

ac5wzw00005802

Catalytic converter installation bolt and nuts tightening torque
45—62 N·m {4.6—6.3 kgf·m, 34—45 ft·lbf}

3.  After installation, verify that the tightening torque for the bolt and nuts is correct.


Catalytic converter bracket installation note (2WD) (Fuel injector (2pin type))

1.  Temporarily tighten bolts 1 and bolt 2 shown in the figure.

ac5wzw00005803

2.  Tighten bolts 1 shown in the figure.

Catalytic converter upper bracket installation bolt (engine side) tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

3.  Tighten bolts 2 shown in the figure.

Catalytic converter upper bracket installation bolt (catalytic converter side) tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

4.  All the conclusions check after attachment whether it is the right torque.

5.  Temporarily tighten bolts 3 and bolt 4 shown in the figure.

ac5wzw00005804

6.  Tighten the bolts in the order shown in the figure.

Catalytic converter lower bracket installation bolt tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

7.  Temporarily tighten bolts 5 and bolt 6 shown in the figure.

ac5wzw00005805

8.  Tighten the bolts in the order shown in the figure.

Catalytic converter lower bracket installation bolt tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

9.  All the conclusions check after attachment whether it is the right torque.


Catalytic converter insulator installation note (2WD) (Fuel injector (2pin type))

1.  Temporarily tighten the catalytic converter insulator installation bolts.

2.  Tighten the bolts in the order shown in the figure.

ac5wzw00005806

Catalytic converter insulator installation bolt tightening torque
8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}


Exhaust System Removal/Installation (4WD) (Fuel injector (2pin type))

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove in the order shown in the figure.

3.  Remove the exhaust system insulator. (See Exhaust system insulator removal/installation (4WD) (Fuel injector (2pin type)).)

4.  Install in the reverse order of removal.

Step 1

ac5wzw00005807

1
Main silencer
2
Middle pipe

Step 2

ac5wzw00014361

1
Insulator
(See Insulator removal note (4WD) (Fuel injector (2pin type)).)
2
Catalytic converter insulator
(See Catalytic converter insulator installation note (4WD) (Fuel injector (2pin type)).)
3
Exhaust gas pressure hose
4
Catalytic converter upper bracket
(See Catalytic converter bracket installation note (4WD) (Fuel injector (2pin type)).)
5
Catalytic converter lower bracket
(See Catalytic converter lower bracket removal note (4WD) (Fuel injector (2pin type)).)
(See Catalytic converter bracket installation note (4WD) (Fuel injector (2pin type)).)
6
Catalytic converter
(See Catalytic converter removal note (4WD) (Fuel injector (2pin type)).)
(See Catalytic converter installation note (4WD) (Fuel injector (2pin type)).)
(See Operation After Replacing Catalytic Converter.)


Exhaust system insulator removal/installation (4WD) (Fuel injector (2pin type))

1.  Remove the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

2.  Remove in the order shown in the figure.

3.  Install in the reverse order of removal.

ac5wzw00013596

1
Insulator (rear)
(See Insulator (rear) removal note (4WD) (Fuel injector (2pin type)).)
2
Insulator (middle)
3
Insulator (front)


Insulator (rear) removal note (4WD) (Fuel injector (2pin type))

Note
•  If re-installed, use the same rivets.

1.  Using a hammer and punch (diam. 2—2.8 mm {0.08—0.11}), punch out the mandrel.

ac5wzw00005810

2.  Pull out and remove the flange using a drill (diam. 5 mm {0.2 in})

ac5wzw00005811


Insulator removal note (4WD) (Fuel injector (2pin type))

1.  Remove the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

2.  Remove the cowl grille (See COWL GRILLE REMOVAL/INSTALLATION.).

3.  Disconnect the windshield wiper de-icer connector. (See WINDSHIELD REMOVAL.)(See WINDSHIELD INSTALLATION.)

4.  Remove the windshield wiper motor and link. (See WINDSHIELD WIPER MOTOR AND LINK REMOVAL/INSTALLATION.)

5.  Remove the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION.)

6.  Remove the insulator.


Catalytic converter lower bracket removal note (4WD) (Fuel injector (2pin type))

1.  Remove the front crossmember. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

2.  Remove the catalytic converter lower bracket.


Catalytic converter removal note (4WD) (Fuel injector (2pin type))

1.  Disconnect the exhaust temperature sensor No.2 connector.

2.  Disconnect the exhaust temperature sensor No.3 connector.

3.  Remove the exhaust temperature sensor No.3 wiring harness bracket installation nuts. (See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

4.  Disconnect the A/F sensor connector.

5.  Remove the catalytic converter.


Catalytic converter installation note (4WD) (Fuel injector (2pin type))

1.  Temporarily tighten bolt and nuts shown in the figure.

ac5wzw00005801

2.  Tighten the bolt and nuts in the other shown in the figure.

ac5wzw00005802

Catalytic converter installation bolt and nuts tightening torque
45—62 N·m {4.6—6.3 kgf·m, 34—45 ft·lbf}

3.  After installation, verify that the tightening torque for the bolt and nuts is correct.


Catalytic converter bracket installation note (4WD) (Fuel injector (2pin type))

1.  Temporarily tighten bolts 1 and bolt 2 shown in the figure.

ac5wzw00005803

2.  Tighten bolts 1 shown in the figure.

Catalytic converter upper bracket installation bolt (engine side) tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

3.  Tighten bolts 2 shown in the figure.

Catalytic converter upper bracket installation bolt (catalytic converter side) tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

4.  All the conclusions check after attachment whether it is the right torque.

5.  Temporarily tighten bolts 3 and bolt 4 shown in the figure.

ac5wzw00005804

6.  Tighten the bolts in the order shown in the figure.

Catalytic converter lower bracket installation bolt tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

7.  Temporarily tighten bolts 5 and bolt 6 shown in the figure.

ac5wzw00005805

8.  Tighten the bolts in the order shown in the figure.

Catalytic converter lower bracket installation bolt tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

9.  All the conclusions check after attachment whether it is the right torque.


Catalytic converter insulator installation note (4WD) (Fuel injector (2pin type))

1.  Temporarily tighten the catalytic converter insulator installation bolts.

2.  Tighten the bolts in the order shown in the figure.

ac5wzw00005806

Catalytic converter insulator installation bolt tightening torque
8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}


Exhaust System Removal/Installation (2WD) (Fuel injector (6pin type))

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove in the order shown in the figure.

3.  Remove the exhaust system insulator. (See Exhaust system insulator removal/installation (2WD) (Fuel injector (6pin type)).)

4.  Install in the reverse order of removal.

Step 1 (Without SCR system)

ac5wzw00005796

1
Main silencer
2
Plate
3
Brace bar
(See Brace bar removal note (2WD) (Fuel injector (6pin type)).)
4
Tunnel member
5
Middle pipe

Step 1 (With SCR system)

ac5uuw00008634

1
Main silencer
2
Insulator
3
Brace bar
(See Brace bar removal note (2WD) (Fuel injector (6pin type)).)
4
Tunnel member
5
NOx sensor No.1
(See NOx SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
6
Urea injector
(See UREA INJECTOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
7
Exhaust gas temperature sensor No.5
(See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
8
NOx sensor No.2
(See NOx SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
9
PM sensor
(See PM SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
10
SCR converter

Step 2

ac5wzw00014362

1
Insulator
(See Insulator removal note (2WD) (Fuel injector (6pin type)).)
2
Catalytic converter insulator
(See Catalytic converter insulator removal note (2WD) (Fuel injector (6pin type)).)
(See Catalytic converter insulator installation note (2WD) (Fuel injector (6pin type)).)
3
Exhaust gas pressure hose
4
Catalytic converter upper bracket
(See Catalytic converter bracket installation note (2WD) (Fuel injector (6pin type)).)
5
Catalytic converter lower bracket
(See Catalytic converter lower bracket removal note (2WD) (Fuel injector (6pin type)).)
(See Catalytic converter lower bracket removal note (2WD) (Fuel injector (6pin type)).)
6
Catalytic converter
(See Catalytic converter removal note (2WD) (Fuel injector (6pin type)).)
(See Catalytic converter installation note (2WD) (Fuel injector (6pin type)).)
(See Operation After Replacing Catalytic Converter.)
7
A/F sensor
(See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
8
Exhaust gas temperature sensor No.4 (With SCR system)
(See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
9
Exhaust gas temperature sensor No.3
(See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
10
Exhaust gas temperature sensor No.2
(See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
11
Exhaust gas temperature sensor No.1
(See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
12
Insulator
13
Exhaust gas pressure sensor No.1 component
14
Exhaust manifold insulator
15
Exhaust manifold
(See Exhaust manifold removal note (2WD) (Fuel injector (6pin type)).)
(See Exhaust manifold installation note (2WD) (Fuel injector (6pin type)).)


Exhaust system insulator removal/installation (2WD) (Fuel injector (6pin type))

1.  Remove in the order shown in the figure.

2.  Install in the reverse order of removal.

Without SCR system

ac5wzw00013596

1
Insulator (rear)
(See Insulator (rear) removal note (2WD) (Fuel injector (6pin type)).)
2
Insulator (middle)
3
Insulator (front)

With SCR system

ac5wzw00013597

1
Insulator (rear)
(See Insulator (rear) removal note (2WD) (Fuel injector (6pin type)).)
2
Insulator (middle)
3
Insulator (front)


Insulator (rear) removal note (2WD) (Fuel injector (6pin type))

Note
•  If re-installed, use the same rivets.

1.  Using a hammer and punch (diam. 2—2.8 mm{0.08—0.11 in}), punch out the mandrel.

ac5wzw00005799

2.  Pull out and remove the flange using a drill (diam. 5 mm{0.2 in}).

ac5wzw00005800


Brace bar removal note (2WD) (Fuel injector (6pin type))

1.  Remove the floor and cover. (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

2.  Remove the brace bar.


Insulator removal note (2WD) (Fuel injector (6pin type))

1.  Remove the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

2.  Remove the cowl grille (See COWL GRILLE REMOVAL/INSTALLATION.).

3.  Remove the windshield wiper motor and link. (See WINDSHIELD WIPER MOTOR AND LINK REMOVAL/INSTALLATION.)

4.  Remove the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION.)

5.  Remove the insulator.


Catalytic converter insulator removal note (2WD) (Fuel injector (6pin type))

1.  Disconnect the exhaust gas temperature sensor No.2 connector. (See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

2.  Remove the nut shown in the figure. (See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

ac5wzw00012207

3.  Remove the wiring harness clip shown in the figure.

ac5wzw00012208

4.  Remove the catalytic converter insulator.


Catalytic converter lower bracket removal note (2WD) (Fuel injector (6pin type))

1.  Remove the front crossmember. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

2.  Remove the catalytic converter lower bracket.


Catalytic converter removal note (2WD) (Fuel injector (6pin type))

1.  Disconnect the exhaust gas temperature sensor No.3 connector.

2.  Disconnect the exhaust gas temperature sensor No.4 connector. (With SCR system)

3.  Disconnect the A/F sensor connector.

4.  Remove the catalytic converter.


Exhaust manifold removal note (2WD) (Fuel injector (6pin type))

1.  Remove the turbocharger. (See TURBOCHARGER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

2.  Set the exhaust gas temperature sensor No.1 out of the way. (See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

3.  Remove the exhaust gas pressure sensor No.1 component.

4.  Remove the exhaust manifold insulator.

5.  Remove the exhaust manifold.


Exhaust manifold installation note (2WD) (Fuel injector (6pin type))

1.  Install the new studs to the cylinder head.

2.  Tighten the nuts in the other shown in the figure.

ac5wzw00012209

Tightening torque
40—47 N·m {4.1—4.7 kgf·m, 30—34 ft·lbf}

3.  Tighten the nuts in the other shown in the figure.


Catalytic converter installation note (2WD) (Fuel injector (6pin type))

1.  Temporarily tighten bolt and nuts shown in the figure.

ac5wzw00012210

2.  Tighten the bolt and nuts in the other shown in the figure.

ac8jjw00002109

Tightening torque
45—62 N·m {4.6—6.3 kgf·m, 34—45 ft·lbf}

3.  After installation, verify that the tightening torque for the bolt and nuts is correct.


Catalytic converter bracket installation note (2WD) (Fuel injector (6pin type))

1.  Temporarily tighten bolts 1 and bolt 2 shown in the figure.

ac8jjw00002110

2.  Tighten bolts 1 shown in the figure.

Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

3.  Tighten bolts 2 shown in the figure.

Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

4.  All the conclusions check after attachment whether it is the right torque.

5.  Temporarily tighten bolts 3 and bolt 4 shown in the figure.

ac8jjw00002111

6.  Tighten the bolts in the order shown in the figure.

Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

7.  Temporarily tighten bolts 5 and bolt 6 shown in the figure.

ac8jjw00002112

8.  Tighten the bolts in the order shown in the figure.

Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

9.  All the conclusions check after attachment whether it is the right torque.


Catalytic converter insulator installation note (2WD) (Fuel injector (6pin type))

1.  Temporarily tighten the catalytic converter insulator installation bolts.

2.  Tighten the bolts in the order shown in the figure.

ac8jjw00002113

Tightening torque
8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}


Exhaust System Removal/Installation (4WD) (Fuel injector (6pin type))

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove in the order shown in the figure.

3.  Remove the exhaust system insulator. (See Exhaust system insulator removal/installation (4WD) (Fuel injector (6pin type)).)

4.  Install in the reverse order of removal.

Step 1 (Without SCR system)

ac5wzw00005807

1
Main silencer
2
Middle pipe

Step 1 (With SCR system)

ac5uuw00008643

1
Main silencer
2
NOx sensor No.1
Exhaust gas temperature sensor No.5
(See NOx SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
3
Urea injector
(See UREA INJECTOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
4
Exhaust gas temperature sensor No.5
(See EXHAUST GAS PRESSURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
5
NOx sensor No.2
(See NOx SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
6
PM sensor
(See PM SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
7
SCR converter

Step 2

ac5wzw00014362

1
Insulator
(See Insulator removal note (4WD) (Fuel injector (6pin type)).)
2
Catalytic converter insulator
(See Catalytic converter insulator removal note (4WD) (Fuel injector (6pin type)).)
(See Catalytic converter insulator installation note (4WD) (Fuel injector (6pin type)).)
3
Exhaust gas pressure hose
4
Catalytic converter upper bracket
(See Catalytic converter bracket installation note (4WD) (Fuel injector (6pin type)).)
5
Catalytic converter lower bracket
(See Catalytic converter lower bracket removal note (4WD) (Fuel injector (6pin type)).)
(See Catalytic converter bracket installation note (4WD) (Fuel injector (6pin type)).)
6
Catalytic converter
(See Catalytic converter removal note (4WD) (Fuel injector (6pin type)).)
(See Catalytic converter installation note (4WD) (Fuel injector (6pin type)).)
(See Operation After Replacing Catalytic Converter.)
7
A/F sensor
(See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
8
Exhaust gas temperature sensor No.4 (With SCR system)
(See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
9
Exhaust gas temperature sensor No.3
(See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
10
Exhaust gas temperature sensor No.2
(See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
11
Exhaust gas temperature sensor No.1
(See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
12
Insulator
13
Exhaust gas pressure sensor No.1 component
14
Exhaust manifold insulator
15
Exhaust manifold
(See Exhaust manifold removal note (4WD) (Fuel injector (6pin type)).)
(See Exhaust manifold installation note (4WD) (Fuel injector (6pin type)).)


Exhaust system insulator removal/installation (4WD) (Fuel injector (6pin type))

1.  Remove the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

2.  Remove in the order shown in the figure.

3.  Install in the reverse order of removal.

Without SCR system

ac5wzw00013596

1
Insulator (rear)
(See Catalytic converter insulator installation note (4WD) (Fuel injector (6pin type)).)
2
Insulator (middle)
3
Insulator (front)

With SCR system

ac5wzw00013597

1
Insulator (rear)
(See Insulator (rear) removal note (4WD) (Fuel injector (6pin type)).)
2
Insulator (middle)
3
Insulator (front)


Insulator (rear) removal note (4WD) (Fuel injector (6pin type))

Note
•  If re-installed, use the same rivets.

1.  Using a hammer and punch (diam. 2—2.8 mm {0.08—0.11}), punch out the mandrel.

ac5wzw00005810

2.  Pull out and remove the flange using a drill (diam. 5 mm {0.2 in})

ac5wzw00005811


Insulator removal note (4WD) (Fuel injector (6pin type))

1.  Remove the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

2.  Remove the cowl grille (See COWL GRILLE REMOVAL/INSTALLATION.).

3.  Disconnect the windshield wiper de-icer connector. (See WINDSHIELD REMOVAL.)(See WINDSHIELD INSTALLATION.)

4.  Remove the windshield wiper motor and link. (See WINDSHIELD WIPER MOTOR AND LINK REMOVAL/INSTALLATION.)

5.  Remove the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION.)

6.  Remove the insulator.


Catalytic converter insulator removal note (4WD) (Fuel injector (6pin type))

1.  Disconnect the exhaust gas temperature sensor No.2 connector. (See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

2.  Remove the nut shown in the figure. (See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

ac5wzw00012207

3.  Remove the wiring harness clip shown in the figure.

ac5wzw00012208

4.  Remove the catalytic converter insulator.


Catalytic converter lower bracket removal note (4WD) (Fuel injector (6pin type))

1.  Remove the front crossmember. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

2.  Remove the catalytic converter lower bracket.


Catalytic converter removal note (4WD) (Fuel injector (6pin type))

1.  Disconnect the exhaust temperature sensor No.3 connector.

2.  Disconnect the exhaust gas temperature sensor No.4 connector. (With SCR system)

3.  Disconnect the A/F sensor connector.

4.  Remove the catalytic converter.


Exhaust manifold removal note (4WD) (Fuel injector (6pin type))

1.  Remove the turbocharger. (See TURBOCHARGER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

2.  Set the exhaust gas temperature sensor No.1 out of the way. (See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

3.  Remove the exhaust gas pressure sensor No.1 component.

4.  Remove the exhaust manifold insulator.

5.  Remove the exhaust manifold.


Exhaust manifold installation note (4WD) (Fuel injector (6pin type))

1.  Install the new studs to the cylinder head.

2.  Tighten the nuts in the other shown in the figure.

ac5wzw00012209

Tightening torque
40—47 N·m {4.1—4.7 kgf·m, 30—34 ft·lbf}

3.  Tighten the nuts in the other shown in the figure.


Catalytic converter installation note (4WD) (Fuel injector (6pin type))

1.  Temporarily tighten bolt and nuts shown in the figure.

ac5wzw00012210

2.  Tighten the bolt and nuts in the other shown in the figure.

ac8jjw00002109

Tightening torque
45—62 N·m {4.6—6.3 kgf·m, 34—45 ft·lbf}

3.  After installation, verify that the tightening torque for the bolt and nuts is correct.


Catalytic converter bracket installation note (4WD) (Fuel injector (6pin type))

1.  Temporarily tighten bolts 1 and bolt 2 shown in the figure.

ac8jjw00002110

2.  Tighten bolts 1 shown in the figure.

Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

3.  Tighten bolts 2 shown in the figure.

Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

4.  All the conclusions check after attachment whether it is the right torque.

5.  Temporarily tighten bolts 3 and bolt 4 shown in the figure.

ac8jjw00002111

6.  Tighten the bolts in the order shown in the figure.

Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

7.  Temporarily tighten bolts 5 and bolt 6 shown in the figure.

ac8jjw00002112

8.  Tighten the bolts in the order shown in the figure.

Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

9.  All the conclusions check after attachment whether it is the right torque.


Catalytic converter insulator installation note (4WD) (Fuel injector (6pin type))

1.  Temporarily tighten the catalytic converter insulator installation bolts.

2.  Tighten the bolts in the order shown in the figure.

ac8jjw00002113

Tightening torque
8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}