™“ FOREIGN MATTER ENTERS. oe

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

5. 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 ie
a) Tilt the welded insulator toward the actuator contact flange. \
b) Install the NEW No.2 insulator behind the welded insulator. OS
c) Install the No.2 insulator bracket behind the exhaust pipe bracket.
NOTE: If the vehicle is not equipped with the welded insulator perform STEP 7 c) d) ONLY.

SMALL INSULATOR FORWARD.

Gj) SLIGHTLY TILT THE a 6,

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

x

Smail Insulator ‘\

INSERT THE S utaror
()) BRACKE THE
EXHAU BRACKET.

\
\ Small Insulator

No. 2 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.
e) 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.

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

Top View:

MAKE SURE TO INSTALL
THEM IN THE CORRECT POSITION.

OK NG

No. 2 Insulator Bracket

Front Exhaust Pipe
Assembly Bracket

6) RETURN THE SMALL INSULSATS&R TO A POSITION
IN WHICH IT WILL NOT ON ACT THE ACTUATOR.

Lo
Th

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 Insulator

INSTALL THE ACTUATOR
BELOW THE FLANGE
ON THE INSULATOR.

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

9. CONNECT THE BYPASS PIPE O
a) Apply clean coolant to the o-ring on gay bypass pipe io ease installation.
r

b) Insert the bypass pipe into the ac as possible.
c) Confirm the bypass pipe andyN tor are positioned correctly.

NOTE: ~S
« DO NOT damage the o- low it to become contaminated before installation.

e Confirm the bypags talled completely, there may be a yellow mark on the new bypass
pipe, DO NOT u i as an installation guide.

it Exhaust Pipe Assembly Bracket

No. 2 Insutator

Exhaust By-pass Pipe

PAY SPECIAL ATTENTION
TO THE POSITION OF THE
L THESE 3 PARTS.

THE FOLLOWING STEPS ARE VITAL. CONFIRM THESE STEPS ARE FOLLOWED CLOSELY.
IF THESE STEPS ARE NOT FOLLOWED A COOLANT LEAK COULD DEVELOP.

aoe Exhaust By-pass Pipe 10. TEMPORARILY INSTALL THE BYPASS PIPE
Pipe Assembly SK . a) Insert the NEW exhaust pipe plate between the bypass
by x pipe bracket and exhaust bracket that is positioned
ae “s if ~ towards the front of the vehicle.
{ A Confirm the plate is installed in the
Exhaust Pipe Plate correct direction, with the tab facing
(The tab should face upward.)

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

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

c) While pressing down on the newly installed exhaust pipe plate son

(“> ib, exhaust pipe plate.

aL

Pa

(d)) SHOULD BE

11. 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.

Valve Plate

10

VITAL STEPS CONTINUED
b) Position the actuator so that approximately 4.5mm of the

a eat valve pin is protruding past the actuator hook.
Tb fy c) Tighten the 3 bolts evenly following the torque sequence
= ) ms shown in the illustration.
— kee | Torque: 44 in.Ibf (5.0N-m

d) Measure the length of the valve pin that protrudes beyond

fhe actuator hook.
ADJUST THE INSTALLATION POSITION.

Specification: 3.5 — 6.5mm
Zin oe . If the protruding pin length i Gi
2 specification, the 3 actuator Melts ST
be loosened and ALL o
a

Atel, Hf be repeated.

YW

3.51065 mm
{ Valve Pin

12. SETTLE THE BYPASS PIPE O-RING
a) Loosen the 2 bypass pipe bolts slightly. DO NO
b) Move the bypass pipe up and down to prop

ove the bolts.
le‘the o-ring.

Gia If this step is not performed, a S&olant leak WILL develop.

EVR H ela ae eee Ma la y,, b) AFTER ADJUSTMENT
A. Ls
Upper part of the O-fig8 f Even )

is deformed. {a
Exhaust Pipe Gas Cabin 1 QO

Even
SETTLE THE O-RING.
VO aot — MOVEUP
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