EGR VALVE INSTALLATION

PROCEDURE


  1. INSTALL EGR VALVE GASKET


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

  2. INSTALL EGR VALVE ASSEMBLY

    Tech Tips

    Perform the Inspection After Repair after replacing the EGR valve assembly.

    Click here


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

    2. Using "TORX" socket wrench E6, install the EGR valve assembly to the EGR cooler assembly and intake manifold with the 2 stud bolts.

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

    3. Temporarily install the 4 nuts.

      Tech Tips

      Fully tighten the 4 nuts when installing the EGR valve bracket.

  3. INSTALL EGR VALVE BRACKET (for LHD)


    1. Temporarily install the EGR valve bracket to the EGR valve assembly, EGR cooler assembly, camshaft housing sub-assembly and timing chain cover assembly with the 2 bolts and 2 nuts.

    2. B0046NKE01

      Fully tighten the 2 bolts and 6 nuts.

      Torque:
      Nut A
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
      Nut B
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Bolt C and Nut C
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    3. Engage the 4 clamps to connect the wire harness to the intake manifold.

    4. Connect the purge valve (purge VSV) connector.

    5. Connect the EGR valve assembly connector.

  4. INSTALL EGR VALVE BRACKET (for RHD)


    1. Temporarily install the EGR valve bracket to the EGR valve assembly, EGR cooler assembly, camshaft housing sub-assembly and timing chain cover assembly with the 2 bolts and 2 nuts.

    2. B0046NKE01

      Fully tighten the 2 bolts and 6 nuts.

      Torque:
      Nut A
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
      Nut B
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Bolt C and Nut C
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    3. Engage the 3 clamps to connect the wire harness to the intake manifold.

    4. Connect the purge valve (purge VSV) connector

    5. Connect the EGR valve assembly connector.

  5. CONNECT NO. 2 WATER BY-PASS HOSE


    1. Connect the No. 2 water by-pass hose to the EGR valve assembly and slide the hose clip to secure it.

  6. INSTALL NO. 3 WATER BY-PASS HOSE


    1. Engage the clamp to install the No. 3 water by-pass hose to the hose clamp.

      Note

      Install the hose with the paint mark facing the upper side of the engine.

    2. Connect the No. 3 water by-pass hose to the EGR valve assembly and EGR cooler assembly, and slide the 2 hose clips to secure them.

  7. ADD ENGINE COOLANT

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  8. INSPECT FOR COOLANT LEAK

    Click here

  9. INSTALL NO. 1 ENGINE COVER

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  10. INSTALL OUTER COWL TOP PANEL


  11. INSTALL INNER COWL TOP TO COWL BRACE


  12. INSTALL FRONT NO. 1 VENTILATOR SEAL


  13. INSTALL FRONT AIR SHUTTER SEAL RH


  14. INSTALL WINDSHIELD WIPER MOTOR AND LINK

    Click here

  15. PERFORM INITIALIZATION


    1. Perform the Inspection After Repair after replacing the EGR valve assembly.

      Click here