EGR COOLER INSTALLATION

PROCEDURE


  1. INSTALL EGR COOLER ASSEMBLY


    1. Install the EGR cooler assembly to the cylinder head sub-assembly RH with the bolt and nut.

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

  2. CONNECT NO. 12 WATER BY-PASS HOSE


    1. Connect the No. 12 water by-pass hose to the EGR cooler assembly, and slide the clamp to secure the hose.

  3. INSTALL NO. 3 WATER BY-PASS PIPE


    1. Install the No. 3 water by-pass pipe to the EGR cooler assembly, and slide the clamp to secure the hose.

  4. REMOVE NO. 4 WATER BY-PASS HOSE


    1. Connect the No. 4 water by-pass hose from the No. 3 water by-pass pipe, and slide the clamp to secure the hose.

  5. INSTALL NO. 1 EGR PIPE


    1. Install 2 new gaskets to the No. 1 EGR pipe and EGR cooler assembly.

    2. Install the No. 1 EGR pipe to the exhaust manifold assembly RH and EGR cooler assembly with the 2 bolts and 2 nuts.

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

  6. INSTALL OUTLET HEATER WATER HOSE


    1. Install the outlet heater water hose to the No. 2 water by-pass pipe and heater pipe, and slide the 2 clamps to secure the hoses.

  7. INSTALL INLET HEATER WATER HOSE


    1. Install the inlet heater water hose to the No. 3 water by-pass pipe and heater pipe, and slide the 2 clamps to secure the hoses.

  8. INSTALL FENDER APRON BRACE SUB-ASSEMBLY RH


    1. Install the fender apron brace sub-assembly RH to the body with the 2 bolts.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

    2. Attach the clamp and connect the hose to the fender apron brace sub-assembly RH.

  9. INSTALL INVERTER MOTOR CABLE BRACKET ASSEMBLY


    1. Temporarily install the inverter motor cable bracket assembly to the inverter assembly with the 2 bolts.

    2. Tighten the 2 bolts.

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

    3. Attach the 3 clamps and connect the generator cable and motor cable to the inverter motor cable bracket assembly.

  10. INSTALL EGR VALVE ASSEMBLY

    Click here

  11. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

    Click here

  12. CONNECT MOTOR CABLE (for LHD)

    Click here

  13. CONNECT GENERATOR CABLE (for LHD)

    Click here

  14. INSTALL INVERTER TERMINAL COVER (for LHD)

    Click here

  15. INSTALL CONNECTOR COVER (for LHD)

    Click here

  16. INSTALL SERVICE PLUG GRIP (for LHD)

    Click here

  17. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL (for LHD)

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Click here