RM3660EC _51 Engine / Hybrid System _080792 NR Series EMISSION CONTROL _0392498 MONOLITHIC CONVERTER A

NR Series EMISSION CONTROL MONOLITHIC CONVERTER REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during exhaust manifold converter sub-assembly (TWC: Front Catalyst) removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
· Replacement of air fuel ratio sensor (sensor 1) · Gas leak from exhaust system is repaired	Inspection after repair	· Poor idle, etc. · Engine start function, etc.	(201906,999999,_51,_080777,_0393969,RM100000001I1RE,)

CAUTION:: ·

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

·

To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

PROCEDURE

Hide Display 1.REMOVE INTERCOOLER ASSEMBLY

Click hereEngine / Hybrid System>NR Series (INTAKE / EXHAUST)>INTERCOOLER>REMOVAL201906,999999,_51,_080791,_0392519,RM100000001HRDK,

Hide Display 2.REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click hereVehicle Exterior>WIPER / WASHER>FRONT WIPER MOTOR>REMOVAL201906,202304,_59,_080767,_0392873,RM100000001HTNQ,202304,202307,_59,_080767,_0392873,RM100000002AYHJ,202307,999999,_59,_080767,_0392873,RM100000002CL7Q,

Hide Display 55737B 3.REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

Click hereSuspension>FRONT SUSPENSION>FRONT SHOCK ABSORBER>REMOVAL201906,202007,_53,_080764,_0392681,RM100000001HS6H_01_0045,202007,202104,_53,_080764,_0392681,RM100000001NG0S_01_0045,202104,202304,_53,_080764,_0392681,RM100000001W5KX_01_0045,202304,202307,_53,_080764,_0392681,RM100000002BA6Q_01_0045,202307,999999,_53,_080764,_0392681,RM100000002CW5B_01_0045,

Hide Display 55701J 4.REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

Click hereSuspension>FRONT SUSPENSION>FRONT SHOCK ABSORBER>REMOVAL201906,202007,_53,_080764,_0392681,RM100000001HS6H_01_0036,202007,202104,_53,_080764,_0392681,RM100000001NG0S_01_0036,202104,202304,_53,_080764,_0392681,RM100000001W5KX_01_0036,202304,202307,_53,_080764,_0392681,RM100000002BA6Q_01_0036,202307,999999,_53,_080764,_0392681,RM100000002CW5B_01_0036,

Hide Display 55225C 5.REMOVE DASH PANEL HEAT INSULATOR

Hide Display 53289A 6.REMOVE RADIATOR SUPPORT OPENING COVER

for TFTM Made: Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER (for TFTM Made)>REMOVAL201906,202104,_59,_080736,_0392548,RM100000001HRI9_01_0020,202104,202304,_59,_080736,_0392548,RM100000001VNBB_01_0020,202304,202307,_59,_080736,_0392548,RM100000002AMO3_01_0020,202307,999999,_59,_080736,_0392548,RM100000002CH8T_01_0020,

for GTMC Made: Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER (for GTMC Made)>REMOVAL201906,202007,_59,_080736,_0392547,RM100000001HRI4_01_0020,202007,202107,_59,_080736,_0392547,RM100000001NOTO_01_0020,202107,202304,_59,_080736,_0392547,RM100000001Y798_01_0020,202304,202307,_59,_080736,_0392547,RM100000002AXCM_01_0020,202307,999999,_59,_080736,_0392547,RM100000002CHFA_01_0020,

Hide Display 17751 7.REMOVE INLET NO. 1 AIR CLEANER

Click hereEngine / Hybrid System>NR Series (COOLING)>COOLING FAN MOTOR>REMOVAL201906,999999,_51,_080776,_0392641,RM100000001HRWA_02_0042,

Hide Display 17705 8.REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

Click hereEngine / Hybrid System>NR Series (ENGINE MECHANICAL)>ENGINE ASSEMBLY>REMOVAL201906,202007,_51,_080739,_0391935,RM100000001HN2A_01_0369,202007,202104,_51,_080739,_0391935,RM100000001RPXX_01_0369,202104,202205,_51,_080739,_0391935,RM100000001WEPZ_01_0369,202205,202304,_51,_080739,_0391935,RM1000000022ZNY_01_0369,202304,999999,_51,_080739,_0391935,RM100000002BCMQ_01_0369,

Hide Display 82121 9.REMOVE ENGINE WIRE

0,0 0,0 false

	Bolt
	Nut
	Connector

Disconnect the 7 connectors.

Remove the bolt and nut.

Disengage the 3 wire harness clamps.

Hide Display 17360A 10.REMOVE AIR TUBE ASSEMBLY

Remove the bolt and separate the air tube assembly from the cylinder head cover sub-assembly.

1.823,1.198 2.208,1.198 true 1.292,0.51 1.49,0.51 1.49,0.51 1.698,0.833 true 2.24,1.115 2.49,1.302 0.25,0.188 10 true *1 1.115,0.427 1.292,0.615 0.177,0.188 10 true *2

*1	No. 2 Intercooler Water Hose
*2	No. 3 Intercooler Water Hose

Slide the 2 clips and disconnect the No. 2 intercooler water hose and No. 3 intercooler water hose from the turbocharger sub-assembly.

1.521,1.365 1.917,1.365 true 0.854,1.031 1.25,1.031 true 1.938,1.292 2.198,1.49 0.26,0.198 10 true *1 0.625,0.958 0.865,1.156 0.24,0.198 10 true *2

*1	No. 2 Intercooler Water Hose
*2	No. 3 Intercooler Water Hose

Disconnect the No. 2 intercooler water hose and No. 3 intercooler water hose from the No. 1 water hose clamp bracket.

Loosen the hose clamp and remove the air tube assembly from the turbocharger sub-assembly.

Hide Display 25819 11.REMOVE VACUUM REGULATING VALVE ASSEMBLY

Click hereEngine / Hybrid System>NR Series (EMISSION CONTROL)>VACUUM REGULATING VALVE>REMOVAL201906,999999,_51,_080792,_0392499,RM100000001HRBS,

Hide Display 25861A 12.REMOVE NO. 2 VACUUM SWITCHING VALVE BRACKET

Remove the 3 bolts and No. 2 vacuum switching valve bracket from the cylinder head sub-assembly.

Hide Display 17301C 13.REMOVE INLET NO. 1 AIR DUCT SUB-ASSEMBLY

Disconnect the No. 1 vacuum transmitting hose assembly from the vacuum tank.

Disengage the 2 clamps and disconnect the No. 1 vacuum transmitting hose assembly.

1.292,1.844 1.292,1.51 true 2.458,1 2.167,1 true 2.563,0.938 2.771,1.104 0.208,0.167 10 true *a 1.219,1.896 1.427,2.083 0.208,0.188 10 true *b

*a	Ventilation Hose
*b	No. 4 Ventilation Hose

Remove the bolt and ventilation hose from the inlet No. 1 air duct sub-assembly.

Remove the bolt and No. 4 ventilation hose from the inlet No. 1 air duct sub-assembly.

Remove the 3 bolts and No. 1 turbo insulator from the vacuum tank.

Remove the 2 bolts and vacuum tank from the inlet No. 1 air duct sub-assembly.

Disconnect the No. 1 vacuum transmitting hose assembly from the vacuum pump assembly.

Disengage the 3 clamps and remove the No. 1 vacuum transmitting hose assembly from the inlet No. 1 air duct sub-assembly.

Remove the bolt and disconnect the inlet No. 1 air duct sub-assembly from the fuel pump protector.

Disconnect the intake air control valve (air by-pass valve assembly) connector.

2.198,0.802 2.792,0.802 true 1.677,1.354 1.948,1.979 1.948,1.979 2.135,1.979 true 2.813,0.729 3.052,0.917 0.24,0.188 10 true *1 2.167,1.906 2.427,2.083 0.26,0.177 10 true *2

*1	No. 3 Vacuum Transmitting Hose Assembly
*2	Inlet No. 1 Air Duct Sub-assembly

Disconnect the No. 3 vacuum transmitting hose assembly from the turbocharger sub-assembly.

Loosen the hose clamp and remove the inlet No. 1 air duct sub-assembly from the turbocharger sub-assembly.

Hide Display 89467B 14.REMOVE AIR FUEL RATIO SENSOR

Click hereEngine / Hybrid System>NR Series (ENGINE CONTROL)>AIR FUEL RATIO SENSOR (for Sensor 1)>REMOVAL201906,999999,_51,_080777,_0392347,RM100000001HQ2X,

Hide Display 12611 15.REMOVE NO. 1 ENGINE COVER

Remove the No. 1 engine cover from the cylinder head cover sub-assembly and cylinder head sub-assembly.

Hide Display 58166A 16.REMOVE FRONT FLOOR COVER LH

Click hereEngine / Hybrid System>NR Series (INTAKE / EXHAUST)>EXHAUST PIPE>REMOVAL201906,999999,_51,_080791,_0392520,RM100000001HREM_01_0043,

Hide Display 58165C 17.REMOVE FRONT FLOOR COVER RH

HINT:: Perform the same procedure as for the front floor cover LH.

Hide Display 57533B 18.REMOVE FRONT FLOOR CENTER BRACE

Click hereEngine / Hybrid System>NR Series (INTAKE / EXHAUST)>EXHAUST PIPE>REMOVAL201906,999999,_51,_080791,_0392520,RM100000001HREM_01_0045,

Hide Display 17410 19.REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

CAUTION:: ·

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

·

To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

Disconnect the air fuel ratio sensor connector.

Disengage the wire harness clamp.

Remove the 4 bolts and 4 compression springs and disconnect the front exhaust pipe assembly (TWC: Rear Catalyst) from the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and tail exhaust pipe assembly.

Remove the front exhaust pipe assembly (TWC: Rear Catalyst) from the 2 exhaust pipe supports.

Remove the 2 gaskets from the exhaust manifold (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst).

Hide Display 58151 20.REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR

Click hereDrivetrain>K313 (CVT)>TRANSMISSION CONTROL CABLE (for TFTM Made)>REMOVAL201906,202205,_52,_080728,_0392273,RM100000001HTPW_02_0019,202205,202304,_52,_080728,_0392273,RM1000000022ZAQ_02_0019,202304,999999,_52,_080728,_0392273,RM100000002BCJQ_02_0019,

Hide Display 17163 21.REMOVE NO. 1 HEAT INSULATOR BRACKET

CAUTION:: To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

HINT:: Perform this procedure when it is necessary to replace the No. 1 heat insulator bracket.

Loosen the 3 bolts of the manifold support bracket.

NOTICE:: ·

Distortion may have occurred due to high temperatures.

·

Do not remove the 3 bolts. Only loosen them.

Remove the bolt, nut and drive shaft heat insulator sub-assembly from the No. 1 heat insulator bracket and manifold support bracket.

Type A:

Remove the bolt and No. 1 heat insulator bracket from the cylinder block sub-assembly.

Type B:

Remove the 2 bolts and No. 1 heat insulator bracket from the cylinder block sub-assembly.

Hide Display 12321B 22.REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

CAUTION:: To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

Loosen the 3 bolts of the manifold support bracket.

NOTICE:: ·

Distortion may have occurred due to high temperatures.

·

Do not remove the 3 bolts. Only loosen them.

Remove the bolt, nut and drive shaft heat insulator sub-assembly from the No. 1 heat insulator bracket and manifold support bracket.

Hide Display 25591 23.REMOVE MANIFOLD SUPPORT BRACKET

CAUTION:: To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

Remove the 3 bolts and manifold support bracket from the cylinder block sub-assembly and exhaust manifold converter sub-assembly (TWC: Front Catalyst).

Hide Display 17272 24.REMOVE NO. 2 TURBO INSULATOR

CAUTION:: To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

Remove the 2 bolts and No. 2 turbo insulator from the cylinder head sub-assembly and heat insulator bracket.

Hide Display 25586 25.REMOVE NO. 1 MANIFOLD CONVERTER INSULATOR

CAUTION:: To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

Remove the 3 bolts and No. 1 manifold converter insulator from the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

Hide Display 25051 26.REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)

CAUTION:: To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

Remove the 4 nuts and exhaust manifold converter sub-assembly (TWC: Front Catalyst) from the turbocharger sub-assembly.

Hide Display 17279 27.REMOVE OUTLET TURBINE ELBOW GASKET

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