NR Series EMISSION CONTROL  MONOLITHIC CONVERTER  INSTALLATION  

0.542,0.656 0.719,0.833 0.177,0.177 10 true 2 1.927,0.417 2.104,0.594 0.177,0.177 10 true 1 1.354,1.583 1.531,1.76 0.177,0.177 10 true 3 1.313,0.021 1.5,0.188 0.188,0.167 10 true 4

Tighten the 4 nuts in the order shown in the illustration.

Torque:

40 N*m (408 kgf*cm, 30 ft.*lbf)

1.208,1.615 1.365,1.813 0.156,0.198 10 true 2 1.865,0.458 2.021,0.656 0.156,0.198 10 true 1 1.604,1.167 1.76,1.365 0.156,0.198 10 true 3

Tighten the 3 bolts in the order shown in the illustration.

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf)

1.958,0.052 2.115,0.25 0.156,0.198 10 true 2 2.5,1.958 2.656,2.156 0.156,0.198 10 true 1

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

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf)

Temporarily install the manifold support bracket to the cylinder block sub-assembly and exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 3 bolts.

NOTICE:

Tighten the 3 bolts until they contact the surface of the manifold support bracket.

1.563,2.073 1.75,2.333 0.188,0.26 10 false *a 1.146,3.073 1.375,3.292 0.229,0.219 10 false *b 2.021,3.083 2.333,3.24 0.313,0.156 10 false *c 2.938,0.99 3.177,1.198 0.24,0.208 10 true *1 1.771,0.563 2.01,0.771 0.24,0.208 10 true *2

*a	Bolt Position
*b	Correct
*c	Incorrect

Temporarily install the driveshaft heat insulator sub-assembly to the No. 1 heat insulator bracket and manifold support bracket with the bolt and nut as shown in the illustration.

NOTICE:

·

Tighten the nut and bolt until they contact the surface of the driveshaft heat insulator sub-assembly.

·

Do not install the drive shaft heat insulator sub-assembly in the uppermost position. If the drive shaft heat insulator sub-assembly is installed in the uppermost position, damage may occur due to stress from distortion caused by high temperatures.

0.906,0.427 1.063,0.625 0.156,0.198 10 true 1 2.958,0.563 3.115,0.76 0.156,0.198 10 true 2

Tighten the bolt and nut in the order shown in the illustration.

Torque:

17.6 N*m (179 kgf*cm, 13 ft.*lbf)

1.563,2.073 1.75,2.333 0.188,0.26 10 false *a 1.146,3.073 1.375,3.292 0.229,0.219 10 false *b 2.021,3.083 2.333,3.24 0.313,0.156 10 false *c 2.938,0.99 3.177,1.198 0.24,0.208 10 true *1 1.771,0.563 2.01,0.771 0.24,0.208 10 true *2

*a	Bolt Position
*b	Correct
*c	Incorrect

Temporarily install the driveshaft heat insulator sub-assembly to the No. 1 heat insulator bracket and manifold support bracket with the bolt and nut as shown in the illustration.

NOTICE:

·

Tighten the nut and bolt until they contact the surface of the driveshaft heat insulator sub-assembly.

·

Do not install the drive shaft heat insulator sub-assembly in the uppermost position. If the drive shaft heat insulator sub-assembly is installed in the uppermost position, damage may occur due to stress from distortion caused by high temperatures.

0.906,0.427 1.063,0.625 0.156,0.198 10 true 1 2.958,0.563 3.115,0.76 0.156,0.198 10 true 2

Tighten the bolt and nut in the order shown in the illustration.

Torque:

17.6 N*m (179 kgf*cm, 13 ft.*lbf)

Using a vernier caliper, measure the free length of the compression springs.

If the free length is less than the minimum, replace the compression spring.

2.813,1.563 2.688,1.563 2.688,1.563 2.385,1.875 false 1.615,3.188 1.99,3.188 1.99,3.188 1.99,2.365 false 1.458,0.667 1.813,0.667 1.813,0.667 1.813,1.125 false 1.292,0.573 1.583,0.792 0.292,0.219 10 false *1 2.854,1.49 3.135,1.698 0.281,0.208 10 false *a 1.448,3.104 1.771,3.344 0.323,0.24 10 false *2

*1	Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst) or Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
*2	Gasket
*a	Wooden Block

Using a plastic hammer and wooden block, tap in the gasket until its surface is flush with the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst).

NOTICE:

·

Be sure to install the gasket in the correct direction.

·

Do not reuse the gasket.

·

Do not damage the gasket.

·

Do not push in the gasket by using the exhaust pipe when connecting it.

Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 2 compression springs and 2 bolts.

Torque:

43 N*m (438 kgf*cm, 32 ft.*lbf)

HINT:

2.406,0.771 2.51,0.167 2.51,0.167 2.677,0.167 false 0.771,0.229 0.906,0.229 0.906,0.229 1.156,0.594 false 0.771,1.198 0.927,1.198 0.927,1.198 1.094,0.896 false 0.406,1.417 0.615,1.573 0.208,0.156 10 *a 0.573,0.146 0.823,0.302 0.25,0.156 10 *1 0.573,1.125 0.813,1.313 0.24,0.188 10 *2 2.698,0.083 2.927,0.26 0.229,0.177 10 *3

*1	Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst)
*2	Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
*3	Gasket
*a	Space between Flanges: 8.5 mm (0.335 in.)

After installation, check that the space between the flanges of the exhaust manifold (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst) is consistent front-to-rear and left-to-right.

Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the tail exhaust pipe assembly with the 2 compression springs and 2 bolts.

Torque:

43 N*m (438 kgf*cm, 32 ft.*lbf)

HINT:

2.396,0.771 2.51,0.167 2.51,0.167 2.677,0.167 false 0.771,0.229 0.906,0.229 0.906,0.229 1.104,0.604 false 0.781,1.188 0.938,1.188 0.938,1.188 1.094,0.885 false 0.406,1.417 0.573,1.573 0.167,0.156 10 *a 0.604,0.177 0.802,0.375 0.198,0.198 10 *1 0.604,1.135 0.813,1.333 0.208,0.198 10 *2 2.719,0.115 2.885,0.271 0.167,0.156 10 *3

*1	Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
*2	Tail 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 (TWC: Rear Catalyst) and tail exhaust pipe assembly is consistent front-to-rear and left-to-right.

1.042,1.469 1.198,1.667 0.156,0.198 10 true 1 1.542,1.604 1.698,1.802 0.156,0.198 10 true 2 2.156,1.646 2.313,1.844 0.156,0.198 10 true 3

Temporarily install the No. 1 turbo insulator to the vacuum tank with the 3 bolts.

0,0 0,0 false

	Bolt
	Nut
	Connector

Engage the 3 wire harness clamps.