REMOVAL AND INSTALLATION <2WD>


caution
  • When the catalytic converter or exhaust centre pipe (DPF) is replaced, use the M.U.T.-III to initialise the learning value (Refer to GROUP 00 - Precautions Before Service, Initialisation Procedure for Learning Value in Common Rail Engine ).
  • When the catalytic converter is replaced, perform the forcible DPF regeneration after learning value in DPF system (Refer to GROUP 17 - Emission Control <Diesel>, DPF System, Forcible DPF Regeneration ).




Catalytic converter removal steps


·
 Fuel filter assembly (Refer to GROUP 13C - Fuel Filter)


·
 Fuel main hose and fuel return hose connection (Refer to GROUP 13B - Fuel Injection Pump)


·
 Fuel line pipe assembly (Refer to GROUP 13B - Fuel Injection Pump)


·
 Steering gear and linkage heat protector (Refer to GROUP 32 - Crossmember) <RHD only>


·
 No.1 exhaust gas temperature sensor [Refer to GROUP 17 - Emission Control <Diesel>, DPF System, DPF System Each Sensor ]


·
 No.2 exhaust gas temperature sensor [Refer to GROUP 17 - Emission Control <Diesel>, DPF System, DPF System Each Sensor ]


·
 No.3 exhaust gas temperature sensor [Refer to GROUP 17 - Emission Control <Diesel>, DPF System, DPF System Each Sensor ]


1.
 Hanger bracket assembly


2.
 Exhaust muffler hanger


3.
 Exhaust pressure pipe front


4.
 Exhaust pressure pipe rear
<<A>>
5.
 Catalytic converter bracket


6.
 Heat cover assembly


7.
 Catalytic converter assembly


8.
 Exhaust pipe gasket


12.
 Exhaust pipe gasket
<<B>>
 >>B<<
 13.
 Rivet


14.
 Front floor heat protector



Exhaust centre pipe removal steps


9.
 Exhaust centre pipe


11.
 Gasket


12.
 Exhaust pipe gasket


15.
 Exhaust muffler hanger
<<B>>
 >>B<<
 16.
 Rivet


17.
 Centre floor heat protector



Exhaust main muffler removal steps


10.
 Exhaust main muffler


11.
 Gasket


18.
 Exhaust muffler hanger

>>A<<
 19.
 Exhaust tail pipe diffuser <some models>


20.
 Rear floor heat protector

REMOVAL SERVICE POINTS

<<A>> CATALYTIC CONVERTER ASSEMBLY REMOVAL
Remove the catalytic converter mounting nut, and pull out the catalytic converter assembly towards the upper side of the engine compartment.

<<B>> RIVET REMOVAL
caution Be careful not to damage the heat protector with the drill.

Use a drill (6.0 mm) to make a hole in the rivet to break it, and then remove the rivet.

INSTALLATION SERVICE POINTS

>>A<< EXHAUST TAIL PIPE DIFFUSER INSTALLATION
When the part is reused, make sure that there is no excessive play after installation and that the part is securely fixed.

>>B<< RIVET INSTALLATION

Use a rivet tool shown in the illustration to connect the parts with rivets by the following procedures.
1.Insert the rivet into a corresponding location.
2.Set the rivet tool at a portion A of rivet.
3.While pushing the flange surface of the rivet onto parts to be fixed with the rivet tool, press the handle of the tool.
4.Thin part of portion A of the rivet will be cut off and the parts is fixed in position.