EXHAUST PIPE GAS CONTROL ACTUATOR INSTALLATION

PROCEDURE

1. INSTALL EXHAUST PIPE GAS CONTROL ACTUATOR SUB-ASSEMBLY

   
   

   1. 

      Clean the installation surfaces and bolt holes of the exhaust pipe gas control actuator sub-assembly and front exhaust pipe assembly (TWC: Front and Rear Catalyst).

      Note

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

   2. 

      *a	Flange
      *b	Fill up
      	Engine Coolant

      If the engine coolant spilled when removing the front exhaust pipe assembly (TWC: Front and Rear Catalyst), 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. 

      *1	Front Exhaust Pipe Assembly (TWC: Front and Rear Catalyst)
      *2	No. 2 Exhaust Pipe Heat Insulator

      Set the No. 2 exhaust pipe heat insulator on the front exhaust pipe assembly (TWC: Front and Rear Catalyst).

      Note

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

   4. 

      *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.

   5. 

      *1	Front Exhaust Pipe Assembly (TWC: Front and Rear Catalyst)
      *2	No. 2 Exhaust Pipe Heat Insulator
      *3	Exhaust Pipe Gas Control Actuator Sub-assembly
      *a	Pin Top Plate
      *b	Hook

      Set the exhaust pipe gas control actuator sub-assembly on the front exhaust pipe assembly (TWC: Front and Rear Catalyst) as a set from the vehicle front.

   6. 

      Loosely install the 3 bolts several threads.

   7. 

      *1	Exhaust By-pass Pipe
      *2	O-ring

      Apply clean engine coolant to the O-ring.

      Note

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

   8. 

      *1	Front Exhaust Pipe Assembly (TWC: Front and Rear Catalyst)
      *2	No. 2 Exhaust Pipe Heat Insulator
      *3	Exhaust By-pass Pipe

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

      Note

      
      

      • Make sure to insert the front exhaust pipe assembly (TWC: Front and Rear Catalyst) into the exhaust pipe gas control actuator sub-assembly as far as possible.

      • Confirm that the front exhaust pipe assembly (TWC: Front and Rear Catalyst), 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 and foreign matter.

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

   9. 

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

      Torque:

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

   10. 

       *a	Valve Plate
       *b	Insertion Direction

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

   11. 

       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 }

   12. 

       *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.)

       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.

          Note

          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.

   13. 

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

       Torque:

       8.5 N*m  { 87 kgf*cm, 6 ft.*lbf }

   14. 

       *a

       Spacer

       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.

          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 (TWC: Front and Rear Catalyst)

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3. ADD ENGINE COOLANT (for Engine)

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4. INSPECT FOR COOLANT LEAK (for Engine)

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