EGR COOLER INSTALLATION

Info Added 2017-10-06

PROCEDURE


  1. INSTALL EGR PIPE WITH COOLER SUB-ASSEMBLY


    1. A001O25

      Using an E8 "TORX" socket wrench, install the 3 stud bolts to the EGR pipe with cooler sub-assembly.

      Tech Tips

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

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

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

    3. Install the EGR pipe with cooler sub-assembly to the EGR valve assembly with the 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. A001S4JC01
      *a 0 to 4 mm (0 to 0.157 in.)
      *b Left Side of Vehicle
      *c Front Side of Vehicle
      *d 180°

      Connect the No. 6 water by-pass hose to the EGR pipe with cooler sub-assembly and slide the clip to secure it.

    5. Install a new EGR cooler gasket to the EGR pipe with cooler sub-assembly.

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

    7. A001P1DC01
      *a Stud Bolt (A)
      *b Stud Bolt (B)
      *c Type A
      *d Type B
      *e 48 mm (1.890 in.)
      *f 26 mm (1.024 in.)
      *g 13 mm (0.512 in.)
      *h 35 mm (1.377 in.)
      *i 20 mm (0.787 in.)
      *j 13 mm (0.512 in.)
      *k 29 mm (1.142 in.)
      *l 14 mm (0.551 in.)
      *m 13 mm (0.512 in.)

      Using an E8 "TORX" socket wrench, install the stud bolt (A) and stud bolt (B) to the cylinder head sub-assembly and camshaft housing sub-assembly.

      Tech Tips

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

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }
    8. A001OHOC01
      B0048I2 Bolt
      B0048S8 Nut

      Temporarily install the EGR pipe with cooler sub-assembly with the EGR valve assembly to the cylinder head sub-assembly and camshaft housing sub-assembly with the bolt and 2 nuts.

    9. A001PLB

      Temporarily install the EGR pipe with cooler sub-assembly to the exhaust manifold (TWC: Front Catalyst) with 2 new nuts.

    10. Tighten the bolt and 2 nuts.

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

    11. Tighten the 2 nuts.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

    12. Connect the EGR valve assembly connector.

  2. CONNECT NO. 4 WATER BY-PASS HOSE


    1. A001Q49C01
      *a Top of Vehicle
      *b Left Side of Vehicle
      *c Paint Mark
      *d 180°
      *e 0 to 4 mm (0 to 0.157 in.)

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

      Tech Tips

      Engage the clip within the area shown in the illustration.

  3. CONNECT INLET HEATER WATER HOSE A


    1. A001QF4C01
      *a Top of Vehicle
      *b Left Side of Vehicle
      *c Paint Mark
      *d 120°

      Connect the inlet heater water hose A to the EGR pipe with cooler sub-assembly and slide the clip to secure it.

      Tech Tips

      Engage the clip within the area shown in the illustration.

  4. CONNECT WATER BY-PASS HOSE


    1. A001Q2XC01
      *a Top of Vehicle
      *b Left Side of Vehicle
      *c Paint Mark
      *d 180°

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

      Tech Tips

      Engage the clip within the area shown in the illustration.

  5. INSTALL EGR PIPE ASSEMBLY

    Click here

  6. INSTALL FLOW SHUTTING VALVE (WATER VALVE)

    Click here

  7. INSPECT FOR EXHAUST GAS LEAK

    If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

    Tech Tips

    Perform Inspection After Repair after repairing an exhaust gas leak.

    Click here