EGR VALVE INSTALLATION

PROCEDURE


  1. INSTALL EGR VALVE ASSEMBLY

    Tech Tips

    After replacing the EGR valve assembly, perform the Inspection After Repairs Click here.


    1. Install a new EGR valve gasket to the EGR valve assembly.

    2. Install the EGR valve assembly to the EGR cooler assembly with the 2 nuts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
    3. A01W06ME01
      Text in Illustration
      *a

      Upper

      (When the EGR valve assembly is installed on the engine assembly)
      *b Paint Mark

      Connect the No. 1 water by-pass hose to the EGR valve assembly and slide the clip to secure it.

      Tech Tips

      Make sure the direction of the clip is as shown in the illustration.

  2. INSTALL EGR VALVE WITH COOLER ASSEMBLY


    1. Install a new No. 2 EGR pipe gasket to the EGR valve assembly.

    2. Install a new EGR cooler gasket to the EGR pipe connector.

    3. A01W02OE02
      Text in Illustration
      *1 No. 2 EGR Pipe
      *2 EGR Pipe Connector

      Temporarily connect the No. 2 EGR pipe to the EGR valve assembly with the 2 bolts.

    4. Temporarily connect the EGR pipe connector to the EGR cooler assembly with the 2 bolts.

    5. Install a new EGR cooler gasket to the EGR pipe connector.

    6. Install a new EGR inlet gasket to the intake manifold.

    7. Temporarily install the EGR valve with cooler assembly, No. 2 EGR pipe and EGR pipe connector to the cylinder head sub-assembly, cylinder block sub-assembly, intake manifold and exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 4 bolts and 3 nuts.

    8. Tighten the 8 bolts and 3 nuts in the order shown in the illustration.

      A01W4TSE03
      Text in Illustration
      *a Bolt (A) *b Bolt (B)
      *c Bolt (C) *d Nut (A)
      *e Nut (B) - -
      B001O8N Bolt B001OAO Nut
      Torque:
      Bolt (A) and Nut (B)
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }
      Bolt (B)
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      Bolt (C)
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Nut (A)
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    9. Engage the 2 wire harness clamps to the No. 2 EGR pipe.

    10. Temporarily install the 2 EGR valve brackets with the 4 bolts.

    11. A01W0N1E02

      Tighten the 4 bolts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    12. Install the fuel hose bracket to the EGR valve bracket with the engine cover joint.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    13. Connect the No. 4 water by-pass hose to the EGR cooler assembly and slide the clip to secure it.

      A01W4W6E02
      Text in Illustration
      *1 No. 2 Water By-pass Hose *2 No. 3 Water By-pass Hose
      *3 No. 4 Water By-pass Hose - -
      *a 1 to 6 mm (0.0394 to 0.236 in.) *b Paint Mark
      *c Upper *d Left

      Tech Tips

      Make sure the direction of the clip is as shown in the illustration.

    14. Connect the No. 3 water by-pass hose to the EGR cooler assembly and slide the clip to secure it.

      Tech Tips

      Make sure the direction of the clip is as shown in the illustration.

    15. Connect the No. 2 water by-pass hose to the EGR valve assembly and slide the clip to secure it.

      Tech Tips

      Make sure the direction of the clip is as shown in the illustration.

    16. A01W2P4E01
      Text in Illustration
      *a Upper
      *b Front
      *c 75°
      *d 15°
      *b Paint Mark

      Connect the water hose sub-assembly to the EGR cooler assembly and slide the clip to secure it.

      Tech Tips

      Engage the clip within the area shown in the illustration.

    17. Engage the water hose to the hose clamp.

    18. Connect the EGR valve assembly connector.

  3. CONNECT ENGINE WIRE


    1. Connect the engine coolant temperature sensor connector.

    2. Install the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    3. A01W29PE03
      Text in Illustration
      *a Fuel Pump Sub-assembly Connector
      *b Ignition Coil Assembly Connector
      *c Camshaft Position Sensor Connector
      B001O8N Bolt
      B001OAO Nut
      B001NW5 Connector

      Engage the clamp.

    4. Connect the fuel pump sub-assembly connector.

    5. Connect the ignition coil assembly connector.

    6. Connect the 2 camshaft position sensor connectors.

    7. Install the nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    8. Connect the 2 earth wires to the EGR valve bracket with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  4. INSTALL FUEL PUMP PROTECTOR

    Click here

  5. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  6. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  7. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

  8. ADD ENGINE COOLANT (for Engine)

    Click here

  9. INSPECT FOR COOLANT LEAK (for Engine)

    Click here

  10. INSPECT FOR EXHAUST GAS LEAK

    Click here

  11. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

    Click here

  12. PERFORM INITIALIZATION


    1. Perform Inspection After Repair after replacing the EGR valve assembly Click here.