EGR VALVE INSTALLATION

CAUTION / NOTICE / HINT

Note

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE


  1. INSTALL EGR VALVE ASSEMBLY


    1. Using an 8 mm socket wrench, install the EGR valve assembly to the EGR valve bracket with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. B00716SC01
      *a Pin
      *b Hole

      Align and fit the hole of the EGR valve bracket to the pin of the camshaft housing.

    3. Using the 8 mm socket wrench, install the EGR valve assembly with the EGR valve bracket to the camshaft housing with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    4. Using the 8 mm socket wrench, connect the fuel pipe sub-assembly to the EGR valve bracket with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    5. Install the EGR cooler bracket to the EGR valve bracket and water outlet with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    6. B006X2GC01
      *a Retainer
      B006Z38 Push in

      Install the water hose connector sub-assembly to the EGR valve assembly.


      1. Align the water hose connector sub-assembly with the EGR valve assembly, push the water hose connector sub-assembly onto the EGR valve assembly, then push in the retainer to secure the connection.

        Note

        Confirm that the retainer makes a "click" sound when pushed.

      2. Check that the EGR valve assembly and water hose connector sub-assembly are securely connected by pulling on them.

    7. Connect the No. 8 water by-pass hose to the EGR valve assembly and slide the clip to secure it.

  2. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY


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

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

    3. Using an 8 mm socket wrench, install the No. 1 EGR pipe sub-assembly to the intake manifold and EGR valve assembly with the 4 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  3. CONNECT ENGINE WIRE


    1. B006ZORC01
      *a No. 5 Engine Wire Connector
      *b EGR Valve Assembly Connector

      Engage the 2 wire harness clamps to connect the engine wire.

    2. Install the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    3. Connect the EGR valve assembly connector.

    4. Connect the No. 5 engine wire connector.

  4. INSTALL EGR COOLER ASSEMBLY

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  5. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

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  6. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

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  7. ADD ENGINE COOLANT

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  8. INSPECT FOR COOLANT LEAK

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  9. INSPECT FOR EXHAUST GAS LEAK

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