6. ATTACH A CLOTH TO THE UNDERSIDE wire

a) Attach a cloth to the underside of the T to’protect the

bumper during exhaust pipe ey
Kos

Vehicle
Front
7. REMOVE THE EXHAUST PIPE ASSEMBLY
a) Disconnect the 6 hangers and remove the exhaust pis

27 EXHAUST

~~ PIPE
ASSEMBLY,

8, REMOVE THE TAIL EXHAUST PIPE ASSEMBLY
a) Support the tailpipe assembly with a block of wood.
b) Remove the 2 bolts and the 2 compression springs.

Cc. EXHAUST GAS CONTROL ACTUATOR REPLACEMENT

CLEAN
THIS AREA.

ASSEMBLY

1. CLEAN THE AREA AROUND THE EXHAUST GAS CONTROL
ACTUATOR SUB-ASSEMBLY

a) Clean the area shaded in the illustration to prevent foreign
material from entering the cooling system.

2. REMOVE THE EXHAUST GAS aga SUB-

The bolts to be
reused.

The bolts to be
replaced.

a) Remove the 5 bolts then the actu: ass pipe.
Confirm that no forei: aterial
enters the ing syStem when the

secure’ pass pipe, they will be

HI
actuator i Bove
DO ior the 2 bolts that

MAKE SURE THAT NO Oo
FOREIGN MATTER ENTERS,

eas
Installation = G

Surface EN *
Se

. CLEAN THE ACTUATOR CONTACT SURFACE
a) Use a shop cloth to clean the contact surface.

NOTE: Clean from the inside of the flange toward the
outside edge to prevent foreign material from entering the
cooling system.

. ADD COOLANT UP TO THE EDGE OF THE FLANGE
a) To limit the amount of air in the cooling system, add coolant.

NOTE: If a large amount of air enters the cooling system,
the foad on the water pump will increase.

Exhaust

ENGAGE THE HOOK
WITH THE VALVE PIN.

5. CONNECT THE BYPASS PIPE TO THE EXHAUST PIPE GAS
CONTROL ACTUATOR

a) Apply clean coolant to the o-ring on the NEW bypass pipe to
ease installation.
b) Insert the bypass pipe into the actuator as far as possible.

NOTE:

© DO NOT damage the o-ring or allow it to become
contaminated before installation.

¢ Confirm the bypass pipe is installed completely, there

may be a yellow mark on the new bypass pjge, DO NOT
use this mark as an installation guide.

THE FOLLOWING STEPS ARE VITAL. CONFIRM THESE STEPS ARE FOLLOWED CLOSELY
IE THESE STEPS ARE NOT/FOLLOWED A COOLANT LEAK COULD DEVELOP.
Center No. ; Exhaust Bypass Pipe 7. TEMPORARILY INSTALL THE BYPASS PIPE

a) Insert the NEW exhaust pipe plate between the bypass
pipe bracket and exhaust bracket that is positioned
towards the front of the vehicle.

Confirm the plate is installed in the
correct direction, with the tab facing

upward.
b) Loosely install 2 NEW black bolts. nd

Exhaust Pipe Plate
{The tab should face upward )

c) While pressing down on the newly installed exhaust pipe plate tighten th
d) While pressing down on the newly installed No.2 insulator tighten th¢b:
Torque: 7Sin.Ibf (8.5N-m)

HOULD BE
cues FIRST.
Press and hold the

ON ¥ exhaust pipe plate.

(@)SHOULD BI - We

E
TIGHTENED SECOWD

. INSTALL THE EXHAUST GAS CONTROL ACTUATOR
a) Confirm the valve plate is positioned correctly by pressing
the plate.

NOTE: If the valve plate is not positioned correctly, the
final actuator position may be difficult to achieve.

10

VITAL STEPS CONTINUED

Valve Pin

b) Position the actuator so that approximately 4.5mm of the
valve pin is protruding past the actuator hack.

c) Tighten the 3 bolts evenly following the torque sequence
shown in the illustration.

Torque: 44 in.Ibf (5.0N:m)

d) Measure the length of the valve pin that protrudes beyond
the actuator hook.

Specification: 3.5 -— 6.5mm
If the protruding pin length i Gap
ts

specification, the 3 actuator,
be loosened and ALL o'
be repeated.

9. SETTLE THE BYPASS PIPE O-RING

a) Loosen the 2 bolts slightly. DO NOT remove the bolts.

Upper part of the O-|
is deformed.

(
Wa LOOSEN
THE etre

NG

Even

SETTLE THE O-RING.

MOVE UP
k AND DOWN.

11

VITAL STEPS CONTINUED
10, TIGHTEN THE BYPASS PIPE BOLTS

DO NOT press down on the bypass pipe when tightening the bolts, this may cause a
| coolant leak,

¢ It is critical that step a) be performed before b), if these steps are completed in the

incorrect order a coolant leak may develop.

a) While pressing down on the newly installed exhaust pipe plate tighten the bolt.

b)} While pressing down on the newly installed No.2 insulator tighten the bolt.
Torque: 75in.lbf (8.5N-m)

(@) SHOULD BE
TIGHTENED FIRST.

Press and hold the
¥ exhaust pipe plate.

(6) SHOULD BI
TIGHTENED SECOND,

11. REMOVE THE SPACER
a) Remove the spacer from the act

woe Front

Ss Va"
REMOVE THE SPACER.

12

D. EXHAUST PIPE ASSEMBLY INSTALLATION
1. INSTALL THE EXHAUST PIPE ASSEMBLY

a) Install the exhaust pipe assembly in the reverse order of removal, refer to TIS for instructions on exhaust
pipe assembly installation.

e Confirm the NEW exhaust pipe gaskets included in the parts kit are used.
.

@ :
*

Confirm the cloth that was attached to the bumper during exhaust pipe removal is removed.
Confirm the coolant drained from the radiator is reused.
Confirm the coolantis filled and the system is properly bled.
2. INSPECT THE OPERATION OF THE EXHAUST GAS CONTROL ACTUATOR
a) Place the vehicle in ‘Inspection Mode’ and warm the engine to normal operating temperate (>)
b) Confirm the hook of the actuator is fully extended.

With cold engine: With warm engine)

TY

AEE det PNR OL UTE

plant is drained from the radiator using a clean container as this coolant MUST be reused
Ew actuator and bypass pipe are installed and aligned correctly

= cooling system is refilled and bled correctly ‘

e actuator is working correctly by following the inspection in these instructions

If you have any questions regarding this campaign, please contact your regional representative

13