EGR VALVE INSTALLATION

PROCEDURE


  1. INSTALL EGR VALVE ASSEMBLY


    1. A001PI2C02
      *a Claw

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

      Note

      Make sure that the claws of the EGR valve gasket are toward the EGR valve assembly side.

    2. Set the EGR valve assembly to the EGR pipe with cooler sub-assembly.

    3. Using an E8 "TORX" socket wrench, install the stud bolt to the camshaft housing sub-assembly.

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

      Tech Tips

      If a stud bolt is deformed or the threads are damaged, replace it.

    4. Install the EGR valve assembly to the EGR pipe with cooler sub-assembly with the 3 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    5. A001Q66C02
      *a 0 to 4 mm (0 to 0.157 in.)
      *b Top of Vehicle
      *c Left Side of Vehicle
      *d 180°
      *e Paint Mark

      Connect the water by-pass hose to the EGR valve assembly and slide the clip to secure it.

    6. A001P7OC01
      *a 0 to 4 mm (0 to 0.157 in.)
      *b Top of Vehicle
      *c Left Side of Vehicle
      *d 180°

      Connect the No. 6 water by-pass hose to the EGR valve assembly and slide the clip to secure it.

    7. Connect the EGR valve assembly connector.

  2. INSTALL EGR PIPE ASSEMBLY

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  3. INSTALL INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulated gloves.

    Note


    • Be careful not to damage the surrounding components when installing the inverter with converter assembly.

    • To prevent damage to the inverter with converter assembly, do not hold the coolant pipe, bracket or connector when securing the inverter with converter assembly.

    • To prevent damage due to static electricity, do not touch the terminals of the inverter with converter assembly connector.

    • Make sure to seal the inverter with converter assembly with the connector cover assembly or tape (non-residue type) etc., until just before installing the inverter with converter assembly to prevent entry of foreign matter and water.


    1. Remove the rope or equivalent that was securing the inverter with converter assembly.

    2. Temporarily install the inverter with converter assembly with the 5 bolts and 2 nuts.

      Note

      Make sure that the inverter with converter assembly is positioned so that the stud bolts are in contact with the base of the U-shaped portions of the No. 1 inverter bracket.

      A001P5PC01
      *a Correct
      *b Incorrect

    3. Fully tighten the bolt (A).

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      A001R9FN02

    4. Fully tighten the 3 bolts (B).

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    5. Fully tighten the bolt (C).

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    6. Fully tighten the 2 nuts (D).

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  4. CONNECT HV AIR CONDITIONING WIRE

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  5. CONNECT HV FLOOR UNDER WIRE

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  6. CONNECT ENGINE WIRE

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  7. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

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  8. INSTALL BATTERY CLAMP SUB-ASSEMBLY

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  9. INSTALL ECM

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  10. INSTALL SERVICE PLUG GRIP

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  11. INSTALL AUXILIARY BATTERY

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  12. CONNECT ENGINE WIRE

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  13. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)

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  14. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)

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  15. INSTALL COWL BODY MOUNTING REINFORCEMENT LH

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  16. INSTALL COWL BODY MOUNTING REINFORCEMENT RH

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  17. INSTALL WATER GUARD PLATE LH

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  18. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

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  19. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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  20. ADD ENGINE COOLANT (for Engine)

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  21. INSPECT FOR COOLANT LEAK (for Engine)

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  22. INSTALL NO. 1 ENGINE UNDER COVER

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