EXHAUST PIPE GAS CONTROL ACTUATOR INSTALLATION

PROCEDURE


  1. INSTALL EXHAUST PIPE GAS CONTROL ACTUATOR SUB-ASSEMBLY


    1. A005AO4

      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. A005CRKE01
      Text in Illustration
      *1 Flange
      *a Fill up
      A005B9E Engine 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. A005CS8E04
      Text in Illustration
      *1 Front Exhaust Pipe Assembly
      *2 No. 2 Exhaust Pipe Heat Insulator

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

      Note

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

    4. A005E67E01
      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.

    5. A005EDNE05
      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

      Set the exhaust pipe gas control actuator sub-assembly on the front exhaust pipe assembly as a set from the vehicle front.

    6. A005BI2

      Loosely install the 3 bolts several threads.

    7. A005DSDE05
      Text in Illustration
      *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. A005AE3E02
      Text in Illustration
      *1 Front Exhaust Pipe Assembly
      *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 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.

    9. A005EPUE02

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

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }
    10. A005EOVE04
      Text in Illustration
      *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.

    11. A005EK7E03

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


      1. A005CP1E04
        Text in Illustration
        *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.)

        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. A005EPUE02

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

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

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


      1. A005DAXE01
        Text in Illustration
        *1 Spacer

        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

    Click here

  3. ADD COOLANT (for Engine)

    Click here

  4. INSPECT FOR COOLANT LEAK (for Engine)

    CAUTION:

    Do not remove the radiator cap while the engine and radiator are still hot. Pressurized hot engine coolant and steam may be released and cause serious burns.

    Tech Tips

    Be sure to turn the A/C switch off before starting the following inspection.


    1. Turn the power switch off. Check for engine coolant leaks from the front exhaust pipe assembly and the heater hose around the exhaust pipe gas control actuator sub-assembly.

    2. Add engine coolant to the reserve tank and install a radiator cap tester.

    3. Pump the cap tester to 118 kPa (1.2 kgf/cm2, 17 psi), and then check that the pressure does not drop.

      If the reading drops, check for leaks from the front exhaust pipe assembly and the heater hose around the exhaust pipe gas control actuator sub-assembly.

    4. Warm up the engine until the coolant temperature reaches the point that the exhaust pipe gas control actuator sub-assembly starts operating (80°C or more) and check for leaks

      If external leaks are found, replace the exhaust pipe assembly.