EXHAUST PIPE GAS CONTROL ACTUATOR INSTALLATION

PROCEDURE


  1. INSTALL EXHAUST PIPE GAS CONTROL ACTUATOR SUB-ASSEMBLY


    1. A004Y7IE02
      Text in Illustration
      *A w/ Pin Top Plate
      *B w/o Pin Top Plate

      Clean the installation surfaces and bolt holes of the exhaust pipe gas control actuator sub-assembly and front exhaust pipe assembly.

      Note

      Make sure no foreign matter enters the cooling system when the exhaust pipe gas control actuator sub-assembly is removed.

    2. A004X1DE02
      Text in Illustration
      *1 Flange
      *a Fill Up
      B001KON Coolant

      If the engine coolant spilled when removing the front exhaust pipe assembly, add engine coolant up to the bottom edge of the flange as shown in the illustration.

      Tech Tips

      If a large amount of air enters the cooling system, the load on the engine water pump assembly will increase.

    3. w/o Pin Top Plate:


      1. A004XA6E03
        Text in Illustration
        *1 Small Insulator

        Using needle nose pliers, slightly tilt the small insulator in the direction shown by the arrow in the illustration to secure enough space to install the No. 2 exhaust pipe heat insulator.

        Note

        Depending on the date of vehicle production, some vehicles are not equipped with the small insulator.

    4. A004YZWE03
      Text in Illustration
      *A w/ Pin Top Plate
      *B w/o Pin Top Plate
      *1 No. 2 Exhaust Pipe Heat Insulator
      *2 Front Exhaust Pipe Assembly

      Set the No. 2 exhaust pipe heat insulator on the front exhaust pipe assembly.

      Note

      Confirm that the No. 2 exhaust pipe heat insulator is installed in the correct position.

    5. w/o Pin Top Plate:


      1. A004ZOFE03
        Text in Illustration
        *1 Small Insulator

        Tilt the small insulator back toward the No. 2 exhaust pipe heat insulator.

        Note

        Depending on the date of vehicle production, some vehicles are not equipped with the small insulator.

    6. A004XB8E01
      Text in Illustration
      *a Vehicle Front

      Lift the rear side of the No. 2 exhaust pipe heat insulator to allow the exhaust pipe gas control actuator sub-assembly to be installed below the flange on the No. 2 exhaust pipe heat insulator.

    7. w/ Pin Top Plate:


      1. A004VYQE04
        Text in Illustration
        *1 Front Exhaust Pipe Assembly
        *2 No. 2 Exhaust Pipe Heat Insulator
        *3 Exhaust Pipe Gas Control Actuator Sub-assembly
        *4 Pin Top Plate
        *5 Hook

        Loosely install the exhaust pipe gas control actuator sub-assembly, confirm the exhaust pipe gas control actuator sub-assembly is installed below the flange on the No. 2 exhaust pipe heat insulator and that the hook is engaged with the valve pin.

    8. w/o Pin Top Plate:


      1. A004WPEE04
        Text in Illustration
        *1 Front Exhaust Pipe Assembly
        *2 No. 2 Exhaust Pipe Heat Insulator
        *3 Exhaust Pipe Gas Control Actuator Sub-assembly
        *4 Valve Pin
        *5 Hook

        Loosely install the exhaust pipe gas control actuator sub-assembly, confirm the exhaust pipe gas control actuator sub-assembly is installed below the flange on the No. 2 exhaust pipe heat insulator and that the hook is engaged with the valve pin.

    9. A004WW8

      Loosely install the 3 bolts several threads.

    10. A004VTPE04
      Text in Illustration
      *1 Exhaust By-pass Pipe
      *2 O-ring

      Apply clean coolant to the O-ring.

      Note

      Do not damage the O-ring or allow it to become contaminated with foreign matter during work.

    11. Install the exhaust by-pass pipe to the exhaust pipe gas control actuator sub-assembly.

      A004YGTE03
      Text in Illustration
      *A w/o Exhaust Pipe Plate *B w/ Exhaust Pipe Plate
      *1 Front Exhaust Pipe Assembly *2 No. 2 Exhaust Pipe Heat Insulator
      *3 Exhaust By-pass Pipe - -

      Note


      • Make sure to insert the front exhaust pipe assembly into the exhaust pipe gas control actuator as far as possible.

      • Confirm that the front exhaust pipe assembly, exhaust by-pass pipe and No. 2 exhaust pipe heat insulator are positioned correctly.

      • When reusing the exhaust by-pass pipe, inspect the O-ring.

      • If the O-ring has scratches or cuts, replace the exhaust by-pass pipe.

      • Make sure that the O-ring and the fitting section of the exhaust pipe gas control actuator sub-assembly are free of oil or foreign matter.

      • Do not touch the O-ring or fitting section of the exhaust pipe gas control actuator sub-assembly.

    12. w/ Pin Top Plate:


      1. A004WAHE02

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

        Torque:
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    13. w/ Exhaust Pipe Plate:


      1. A00501TE01
        Text in Illustration
        *a Vehicle Front

        Press in the No. 2 exhaust pipe heat insulator to align the installation holes of the exhaust by-pass pipe and No. 2 exhaust pipe heat insulator.

      2. A004X4UE01
        Text in Illustration
        *1 Exhaust By-pass Pipe
        *2 Exhaust Pipe Plate
        *3 Front Exhaust Pipe Assembly

        Insert the exhaust pipe plate between the exhaust by-pass pipe and front exhaust pipe assembly.

      3. A004Y09E01

        While holding down the No. 2 exhaust pipe heat insulator and exhaust pipe plate, fully tighten the 2 bolts in the order shown in the illustration.

        Torque:
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

        Note

        If the procedure is not followed correctly, malfunctions or coolant leaks from the O-ring may occur.

    14. A004VC0E03
      Text in Illustration
      *A w/ Pin Top Plate
      *B w/o Pin Top Plate
      *1 Valve Plate
      *a Insertion direction

      Confirm that the valve plate is positioned correctly by pressing the plate.

      Tech Tips

      If the valve plate is not positioned correctly, the final exhaust pipe gas control actuator sub-assembly position may be difficult to achieve.

    15. w/ Pin Top Plate:


      1. A004WSWE04

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

        Torque:
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    16. w/o Pin Top Plate:


      1. A004YREE03
        Text in Illustration
        *1 Hook
        *2 Valve Pin
        *a 3.5 to 6.5 mm (0.138 to 0.256 in.)
        *b Perpendicular
        *c Adjust the installation position

        Position the exhaust pipe gas control actuator subassembly so that 3.5 to 6.5 mm of the valve pin is protruding past the hook of the exhaust pipe gas control actuator sub-assembly.

      2. Tighten the 3 bolts in the order shown in the illustration in several steps.

        Torque:
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      3. Check that the hook of the exhaust pipe gas control actuator sub-assembly is at a point 3.5 to 6.5 mm from the end of the valve pin.

        Tech Tips


        • If the hook is not installed within the specified range, loosen the 3 bolts of the exhaust pipe gas control actuator sub-assembly and 2 bolts of the exhaust by-pass pipe, then perform the steps from "Temporarily install the 3 bolts several threads".

        • If installation within the specified range cannot be obtained, replace the front exhaust pipe assembly.

    17. Adjust the installation position of the exhaust by-pass pipe.


      1. Loosen the 2 bolts slightly.

        Note

        Do not remove these 2 bolts.

      2. Move the exhaust by-pass pipe up and down to properly settle the O-ring.

        A004ZIQE03
        Text in Illustration
        *A w/ Pin Top Plate *B w/o Pin Top Plate
        *1 Exhaust Pipe Gas Control Actuator Sub-assembly *2 O-ring
        *3 Exhaust By-pass Pipe - -
        *a OK (O-ring is not deformed.) *b NG (O-ring is deformed.)

        Note


        • If this step is not performed, a coolant leak will develop.

        • Make sure to settle the O-ring to distribute the pressure applied to the upper part of the O-ring. Failure to do so may cause engine coolant to leak.

    18. w/ Pin Top Plate:


      1. A004WAHE02

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

        Torque:
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    19. w/o Pin Top Plate:


      1. A004Y09E01

        While holding down the No. 2 exhaust pipe heat insulator and exhaust pipe plate, fully tighten the 2 bolts in the order shown in the illustration.

        Torque:
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    20. When replacing the exhaust pipe gas control actuator sub-assembly with a new one:


      1. Remove the spacer from the new exhaust pipe gas control actuator sub-assembly.

        A004WI6E03
        Text in Illustration
        *A w/ Pin Top Plate *B w/o Pin Top Plate
        *1 Spacer - -

        Note

        To prevent a malfunction of the exhaust pipe gas control actuator sub-assembly, the spacer must be removed.

        Tech Tips

        The spacer is provided with a new exhaust pipe gas control actuator sub-assembly.

  2. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  3. ADD COOLANT (for Engine)

    Click here

  4. INSPECT FOR COOLANT LEAK (for Engine)

    Click here