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EGR COOLER INSTALLATION

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PROCEDURE


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    INSTALL EGR COOLER ASSEMBLY


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

      10 N*m 102 kgf*cm 7 ft.*lbf
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    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.

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    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.

    2. for LHD:

      Install the engine motor cable clamp bracket with the bolt.

      8.0 N*m 82 kgf*cm 71 in.*lbf
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    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.

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    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.

      21 N*m 214 kgf*cm 15 ft.*lbf
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    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.

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    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.

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    INSTALL FENDER APRON BRACE SUB-ASSEMBLY RH


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

      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.

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    INSTALL INVERTER MOTOR CABLE BRACKET ASSEMBLY (for LHD)


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

    2. Tighten the 2 bolts.

      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.

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    INSTALL EGR VALVE ASSEMBLY

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    INSTALL INTAKE AIR SURGE TANK ASSEMBLY

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    CONNECT MOTOR CABLE (for LHD)

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    CONNECT GENERATOR CABLE (for LHD)

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    INSTALL INVERTER TERMINAL COVER (for LHD)

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    INSTALL CONNECTOR COVER (for LHD)

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    INSTALL INVERTER COVER ASSEMBLY RH (for LHD)

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    INSTALL SERVICE PLUG GRIP (for LHD)

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    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.

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