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C. EXHAUST GAS CONTROL ACTUATOR REPLACEMENT

| CLEAN THIS AREA.

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Installation

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Surface NS

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.

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2. REMOVE THE EXHAUST GAS CONTR TUATOR SUB-
ASSEMBLY

a) Remove the 5 bolts then the sande pass pipe.
STOP Confirm that no foreign Materia! enters

the cooling sygkem when the actuator is

oe

3. REMOVE THE HEAT INSULATOR

a) If an old-style heat insulator is present, remove and discard
this part.

NOTE: Depending on the vehicle production date, some
vehicles will be equipped with this insulator and some will
not.

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

NOTE: Ciean 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 load on the water pump will increase.

6. INSPECT FOR WELDED INSULATOR

INSPECTION RESULT | ACTION REQUIRED
Equipped with insulator Perform STEP 7 a) through e)

Not equipped with insulator | Perform STEP 7 c) and d) ONLY

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

Small Insulator ,,,,
7. LOOSELY INSTALL THE No.2 INSULATOR
a) Tilt the welded insulator toward the actuator contact flange. K
b) Install the NEW No.2 insulator behind the welded insulator. YS
c) Install the No.2 insulator bracket behind the exhaust pipe bracket. a>
c)a

NOTE: If the vehicle is not equipped with the welded insulator perform STEP 7 d) ONLY.

(a)) SLIGHTLY TILT THE \ 4
SMALL INSULATOR FORWARD. Oy

SERT THE LOWER PART OF
THE NO. 2 INSULATOR BEHIND
THE SMALL INSULATOR.

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INSERT THE INSULATOR
()) BRACKE THE
EXHAU BRACKET.

No. 2 Insul4tog Bracket : .
: Ke Small Insulator
re

No. 2 Insulator

Small Insulator

Exhaust Pipe Bracket

NOTE: The mesh on the new No.2 insulator is used to prevent rattle and vibration noise.

d) Confirm the new No.2 insulator is installed in the correct position.
€) Tilt the welded insulator back toward the No.2 insulator.

NOTE: If the vehicle is not equipped with the welded insulator perform STEP 7 c) and d) ONLY.

(d)) CONFIRM THAT THE NO. 2 INSULATOR RELATED PARTS
ARE INSTALLED IN THE CORRECT POSITION.

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Top View:

MAKE SURE TO INSTALL
THEM IN THE CORRECT POSITION.

OK NG

No. 2 Insulator Bracket

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Front Exhaust Pipe
| Assembly Bracket

6) RETURN THE SMALL INSU R TO A POSITION
IN WHICH IT WILL NOT CT THE ACTUATOR.

? -_——— _

8. LOOSELY INSTALL THE EXHAUST GAS CONTROL
ACTUATOR

a) Lift the rear side of the No.2 insulator to allow the actuator to
be installed below the flange on the insulator.

b) Loosely install the NEW actuator, confirm the actuator is installed below the flange on the insulator and that
the hook is engaged with the valve pin.

NOTE: Confirm no foreign material is present in the coolant prior to installing the actuator.

No 2 Insulalar

i
INSTALL THE ACTUATOR
BELOW THE FLANGE
ON THE INSULATOR.

c) Loosely install the 3 NEW biack bolts several threads.

NOTE: DO NOT tighte these bolts at this time as the
actuator will nee djusted.

9. CONNECT THE BYPASS PIPE
a) Apply clean coolant to the o-ring on th
b} Insert the bypass pipe into the act

NOTE:

bypass pipe to ease installation.
ras possible.

c) Confirm the bypass pipe “i. tor are positioned correctly.

e DO NOT damage the o-rj
¢ Confirm the bypass pi

llow it to become contaminated before installation.

mefistalled completely, there may be a yellow mark on the new bypass
AS an installation guide.

Exhaust By-pass Pipe

PAY SPECIAL ATTENTION
TO THE POSITION OF THE

THESE 3 PARTS. J

Exhaust By-pass Pipa

a
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Ve fee

\ be ees

Se f

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THE FOLLOWING STEPS ARE VITAL. CONFIRM THESE STEPS ARE FOLLOWED CLOSELY

IF THESE STEPS ARE NOT FOLLOWED A COOLANT LEAK COULD DEVELOP.

10. TEMPORARILY INSTALL THE BYPASS PIPE

Pipe Assembly L., a) Insert the NEW exhaust pipe plate between the bypass
a pipe bracket and exhaust bracket that is positioned
7

Front Exhaust ny ae By-pass Pipe

towards the front of the vehicle.

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

{The fab should face upward.) Sic)

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™~e aye

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a
x
OPE s aE

/ Vehicle

ut Pipe Plate
upward
. (ye FA a// b) Loosely install 2 NEW black bolts. ND

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

SHOULD BE
TIGHTENED FIRST,

Press and hold the
exhaust pipe plate.

11. INSTALL THE EXHAUST GAS CONTROL ACTUATOR

the plate.

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

Insertion Direction

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Valve Plate