HKS Metal Catalyzer Kit Installation Manual

Important Safety Information

Warning: Installation must be performed by qualified professionals. Read this manual thoroughly before proceeding.

Caution: Keep this manual with the product after installation for future reference.

This product is designed for installation only on the vehicles specified. If your vehicle model or specifications differ from those listed, please contact your place of purchase immediately.

Parts List

Product Assembly Diagram

A diagram illustrating the assembly of the HKS Metal Catalyzer Kit components onto the vehicle. It shows the placement of the primary and secondary catalytic converters, A/F sensor, O2 sensor, heat shields, and various brackets and fasteners.

Note: For replacement parts listed in the parts list, they are set as repair parts. Please inquire at your place of purchase.

About A/F and O2 Sensor Removal/Installation

Caution: If the check engine light illuminates after installing this product, it may indicate a damaged A/F or O2 sensor, or a faulty sensor harness connection. Inspect the A/F and O2 sensors and their harnesses for damage or poor connection and repair or replace as necessary.

Reasons for Sensor Malfunction:

• Sensor disconnection
• Poor sensor connector contact
• Sensor heater malfunction
• Vehicle-side harness disconnection or poor contact

Caution: When removing or installing the A/F or O2 sensor, be careful not to damage the sensor or harness. Follow these precautions:

• Remove the sensor only after disconnecting the sensor connector. Attempting to remove the sensor with the connector attached may twist and break the harness.
• Avoid getting oil or dirt on the removed sensor. Contamination can impair sensor function.
• If a sensor replacement was performed due to a sensor error, reset the Engine Control Unit (ECU). Simply replacing the sensor may not clear the error code, potentially causing an error display.

1. Removal of Genuine Parts

When installing or removing genuine parts, use both the manufacturer's service manual and this manual.

1. Remove the genuine primary catalytic converter, genuine secondary catalytic converter, A/F sensor, and O2 sensor.
2. Remove the heat shield from the genuine primary catalytic converter.

Warning: Do not apply lubricant to the rubber stays. If lubricant is used during removal/installation, ensure it is completely cleaned off. Residual lubricant can cause the part to detach during operation, leading to serious accidents.

Parts to be Reused (Handle with care):

• A/F Sensor
• O2 Sensor
• Rubber Stays (x2)
• Pipe Clamp (including bolts)
• Heat Shield attached to the genuine primary catalytic converter (including bolts)

Advice:

• Be careful not to damage the sensor harness when removing sensors.
• The removed genuine primary catalytic converter, genuine secondary catalytic converter, and genuine spherical gasket are not reusable. Store them properly.
• Use the new gasket included in the kit.

Genuine Catalytic Converter Configuration Diagram: A diagram showing the layout of the genuine catalytic converter with A/F sensor and O2 sensor.

2. Installation of Primary Catalytic Converter

1. Install the A/F sensor and tighten to the specified torque.
2. Install the appropriate bracket. This product is compatible with both MT and AT vehicles, and includes brackets for both. (Refer to Figure 1: Primary Catalytic Converter Configuration Diagram)

Figure 1: Primary Catalytic Converter Configuration Diagram: Shows the primary catalytic converter with mounting points for brackets.

Bracket Installation Method:

For MT Vehicles:

Pass the bolt through the spring washer and plain washer. Then, attach the primary catalytic converter bracket, the MT vehicle bracket, and secure with the flange nut. Temporarily tighten. (Refer to Figure 2: MT Vehicle Bracket Assembly Diagram)

Figure 2: MT Vehicle Bracket Assembly Diagram: Illustrates the assembly of the MT vehicle bracket to the primary catalytic converter bracket.

Note: The MT vehicle bracket is installed on the inside of the primary catalytic converter bracket.

For AT Vehicles:

Pass the bolt through the spring washer and plain washer. Then, attach the AT vehicle bracket, the primary catalytic converter bracket, and secure with the flange nut. Temporarily tighten. (Refer to Figure 3: AT Vehicle Bracket Assembly Diagram)

Figure 3: AT Vehicle Bracket Assembly Diagram: Illustrates the assembly of the AT vehicle bracket to the primary catalytic converter bracket.

Note: The AT vehicle bracket is installed on the outside of the primary catalytic converter bracket.

Important: The installation method for the MT and AT vehicle brackets differs. Ensure correct placement during installation.

If Installation is Incorrect:

• If the MT vehicle bracket is installed on the outside of the primary catalytic converter bracket, a gap will form between the bracket and the vehicle mounting surface, potentially causing exhaust leaks when tightened.
• If the AT vehicle bracket is installed on the inside of the primary catalytic converter bracket, it will not fit due to misalignment with the turbo connection surface, potentially causing exhaust leaks when tightened.

(3) Installation of Heat Shield

Attach the heat shield to the genuine heat shield mounting bracket as you would with the genuine part. (Refer to Figure 4: Genuine Heat Shield Installation Reference Diagram)

Figure 4: Genuine Heat Shield Installation Reference Diagram: Shows the genuine heat shield being attached to its bracket.

Tightening Torque: Heat shield bolt: 5 N·m (0.5 kgf·m)

(4) Installation of Primary Catalytic Converter:

Use the genuine pipe clamp and genuine bolts to install the primary catalytic converter in its original location. Tighten to the specified torque.

(5) Tighten Bracket Bolts:

Tighten the bracket bolts to the specified torque.

(6) Reinstall Genuine Parts:

Reinstall the genuine parts that were removed.

Tightening Torques:

• A/F Sensor: 44 N·m (4.5 kgf·m)
• Genuine Pipe Clamp Bolt: 18 N·m (1.8 kgf·m)
• Genuine Flange Nut: 43 N·m (4.4 kgf·m)
• Bracket Bolt: 17 N·m (1.7 kgf·m)

3. Installation of Secondary Catalytic Converter

1. Attach the genuine rubber stays to the two hanging hooks on the secondary catalytic converter.
2. Using the genuine flange bolts, genuine springs, and the supplied spherical gasket (φ70), install the secondary catalytic converter and tighten to the specified torque.
3. Install the O2 sensor and tighten to the specified torque.
4. Secure the O2 sensor harness with the supplied zip tie as shown in Figure 5. (1 location)

Figure 5: Zip Tie Fixing Points: Diagrams showing where to secure the O2 sensor harness with a zip tie.

(5) Installation between Secondary Catalytic Converter and Muffler:

Insert the supplied spherical gasket (φ70) between the secondary catalytic converter and the muffler. Use the genuine flange bolts and genuine springs to install and tighten to the specified torque.

(6) Reinstall Genuine Parts:

Reinstall the genuine parts that were removed.

Tightening Torques:

• Genuine Flange Bolt: 43 N·m (4.4 kgf·m)
• O2 Sensor: 44 N·m (4.5 kgf·m)
• Genuine Bolt: 43 N·m (4.4 kgf·m)

4. Confirmation of Installation Status

1. After installation is complete, check that there is no interference with any parts.
2. Start the engine and run at approximately 2500 RPM to check for exhaust leaks or abnormal noises.
3. Perform a test drive to re-check for exhaust leaks or abnormal noises.

Note: After completing the installation, always perform the confirmation checks as described in the "Post-Installation Checks" section of this manual.

5. Post-Installation Checks

(1) Installing this product may change boost pressure characteristics. If you have modified the boost pressure, check for knocking and maximum boost pressure. Adjust settings as necessary.

Caution:

• Performance may vary depending on individual vehicle characteristics and other parts used. Knocking and other issues may also vary. Exercise caution when installing the product. If problems are identified, consider the current settings and any other parts used.

After completing all checks, reinstall any removed bumper or under cover components.

Maintenance and Management

Perform daily inspections before driving to ensure comfortable operation.

• Daily inspections are the responsibility of the vehicle owner or operator. Ensure these are performed.
• For matters not covered in the user manual, consult a professional.
• Check spark plugs according to driving conditions.
• Change the oil regularly. Use HKS genuine oil for oil changes.

Recommended Interval: Every 3,000 - 5,000 km, or every 3-6 months.

Troubleshooting: Abnormalities and Failures

Warning: If you notice any abnormal sounds or vibrations while driving, stop the vehicle immediately and investigate the cause. If the catalytic converter has detached, do not restart the engine.

• Inform a professional of the situation and request repairs.
• If safe repairs cannot be made on-site, follow instructions for temporary measures. Perform any work only after the catalytic converter has cooled down sufficiently.
• Always follow the instructions of a professional. Failure to do so may result in accidents due to catalytic converter detachment.

Caution: Never attempt to repair product malfunctions yourself. Always consult a professional.

If you notice any unusual noises, odors, or vibrations while driving, refer to the user manual for instructions.

After-Sales Service

For inquiries regarding this product, please contact the installer or your place of purchase.

Notes on Transfer of Ownership

If you transfer ownership of this product, please provide the instruction manual to the next owner. When removing this product from a vehicle, always use a professional installer.

Regarding Exhaust Gas Test Certificate

A copy of the exhaust gas test certificate, compliant with Road Vehicle Act, Article 31, is included with this product. This certificate may be required during periodic inspections. Please keep it in the vehicle at all times.

Note: The "Exhaust Gas Test Certificate" does not guarantee passing the vehicle inspection.

For some vehicle models, the copy of the exhaust gas test certificate includes a field to write the vehicle's chassis number. If applicable, fill in the chassis number of the vehicle after purchase and keep it for your records.