TECHNICAL INSTRUCTIONS

FOR a

LIMITED SERVICE CAMPAIGN CHR ry

EXHAUST GAS CONTROL ACTUATOR R CEMENT

CERTAIN 2011 - 2012 or CT200h

UPDA rept 23, 2012
TECHNICALQNSTAMM@TION UPDATE NOTICE:
Updated 7/23/12
- The operation flow chart has been @y (SECTION 1)

Updated 6/13/12
- Actuator part number informati

the campaign parts kit has been updated (SECTION III}

Previous j of these Technical Instructions should be discarded.

I. OPERATION FLOW CHART

Verify Vehicle Eligibility
1. Check the VIN range.

2. Check the TIS Vehicle Inquiry Not Covered—— No further action required.
System.
Covered
groeecedaccocen,
Q NOTE: The newly designed actuator is o
0 made of metal, the old design was ¢
0 black plastic. There are approximately
@ 200 vehicles involved in this campaign 8 ‘+
g that had the updated actuator installed 0
0 during vehicle assembly. 0 K

Drain the engine coolant from the
radiator draincock piug.

Use a clean container to collect the

coolant, this coolant will be reused.
_

Peeeca
boanoooadse

eee ete

o

0

6

o

@ DO NOT reuse the coolant that is drained @

@ when disconnecting the coolant hoses by 0 “S
o the exhaust pipe as it may be 8

0 contaminated when drained. 0
Se See aa & oo agcedn.: &

ll. IDE ICAFION OF AFFECTED VEHICLES
A. VE VIN RANGE

VIN Range
WMI | Year VDS Range
2011 2000113-2046991
STH [39121 KD5BH [-5957531-2079902
NOTE:

e Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Limited Service Campaign,
and that the campaign has not already been completed prior to dealer shipment or by another dealer.

* TMS warranty will not reimburse dealers for repairs conducted on vehicles that are not affected or were
completed by another dealer.
lil. PREPARATION

A. PARTS
Part Number Part Description Quantity
16492-21050 Radiator Draincock O-Ring 1
04001-88137 Actuator Set, Exhaust Pipe Gas Control Kit* 1
*The kit above includes the following parts:
Part Number Part Description Quantity
17046-21030 | Acuator Sub-Assy, Exhaust Pipe Gas Control 1
17146-37020 Pipe, Exhaust Bypass 1
17537-37010 Plate, Exhaust Pipe 1
17552-37020 insulator, Exhaust Pipe Heat No. 2 1
17457-37010 Bolt (14mm) 2 nN
90105-06335 Bolt (20mm) 3
17451-28040 Gasket, Exhaust Pipe 1
17451-23042 Gasket, Exhaust Pipe No. 2 1 ry

B. TOOLS & EQUIPMENT

e Techstream

e Standard hand tools nN %
* Clean drain bucket Oy

Cc. SUPPLIES
Part Name
Toyota Genuine 50/50 Pre-Diluted SLLC Approxi
NOTE:

¢ The coolant drained from the radiator MUST b :
*« Because some coolant will be lost when disconn®sting the
hoses by the exhaust pipe, a small amou oolant will be

needed.
IV. BACKGROUND ©
| &

On certain 2011 and 2012 model year CT 200h model year vehicles, there is a possibility that the exhaust gas
control actuator may develop a coolant leak. If a coolant leak occurs, the Water Temp Indicator Lamp ( -£ } and
Check Engine Lamp ( ©) will illuminate.

lf the above warning lamps illuminate, the driver should pull over, and contact an authorized Lexus dealer for
diagnosis and repair. Continued operation of the vehicle with insufficient levels of coolant will cause the engine
to overheat.

3

V. WORK PROCEDURE
A. COMPONENTS

NO. 5 EXHAUST
PIPE SUPPORT

HEATER WATER

HOSE INLET ¢ abe -
HEATER WATER
HOSE OUTLETC

@ EXHAUST
PIPE ”
GASKET .-~

@: Replacement part

[Nem (kgf*cm, ft.*Ibf} |: Specified torque

fis? 5.0 (51, 44 in.*ibf}
ux
8.5 (87, 75 in.*Ibf)
NEW Type: Old Type:
x2 _ (equipped on some vehicles)
“es 7 a J, |B @ NO. 2 EXHAUST PIR
md if HEAT INSULATOR
- NEW, Old
EXHAUSTPIPE PLATE ; | i :
; : : Type:
(additional part) a fe ype
4%
@ EXHAUST PIP CONTROL
@ EXHAUST BY-PASS PIPE ACTUATOR SUB- EMBLY
(supplied with an O-ring) (supplied wdttha gasket)

FRONT EXHAUST PIPE ASSEMBLY

WIRING HARNESS
CLAMP BRACKET G

@ NO. 2 EXHAUST
PIPE GASKET

43 (438, 32)

51 (520, 38)

B. FRONT EXHAUST PIPE ASSEMBLY REMOVAL
1. CHECK FOR DTCs
a) Check and record any DTCs and freeze-frame data that may be present.
2. DRAIN THE ENGINE COOLANT
a) Prepare a clean container.
b) Connect a clean hose to the radiator draincock and drain the coolant into a clean container.
c) When the coolant is drained completely, replace the draincock o-ring.

Confirm the cooling system is sufficiently cool before beginning any work.

*
« The coolant drained from the radiator MUST be reused, confirm that a clean cgfitainer is
Gia used when draining the coolant.
se

e DO NOT reuse any coolant that is drained when disconnecting the coolan the
exhaust gas control actuator, this coolant may be contaminated whengirgine
e DONOT mix the coolant drained from the radiator with the coolant dra ine rom the hoses.

Radiator side Exhaust heat recirculation

system side
TK Hose

Reusable Non-reusable

3. REMOVE THE FRONT EXHAUST PIPE ASS&
a) Refer to TIS for instructions on frontaxhaust pipe assembly removal.

AUST
HEATER WATER PORT
HOSE INLET C “& ‘ , FRONT EXHAUST PIPE ASSEMBLY
x
HEATER WATER NO. 2 EXHAUST

PIPE GASKET

EXHAUST —~ a 0 43 (438. 32)
@ cmt

9? a
Ry"
43 (438, 32)
FRONT NO. 3 ENGINE OXYGEN SENSOR ;
UNDER COVER
FRONT CENTER FLOOR BRACE |
te WIRING HARNESS
CLAMP BRACKET C
* , dl, xd
oO 13 (127, 9)
Ox [51 (620, 38))

C. EXHAUST GAS CONTROL ACTUATOR REPLACEMENT

CLEAN THIS AREA. 4. CLEAN THE AREA AROUND THE EXHAUST GAS CONTROL
5a - 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 CONTR TOR SUB-
ASSEMBLY

a} Remove the 5 bolts then the sub pass pipe.
STOP Confirm that no foreign material enters

the cooling system when the actuator is

on

\ MAKE SURE THAT NO