EXHAUST COOLER INSTALLATION

PROCEDURE


  1. INSTALL STUD BOLT

    Note

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


    1. B0046O9E01

      Using E6 and E8 "TORX" socket wrenches, install the 9 stud bolts to the exhaust cooler assembly.

      Torque:
      Stud Bolt (A)
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
      Stud Bolt (B)
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  2. INSTALL STRAIGHT SCREW PLUG

    Note

    If coolant leaks from a straight screw plug or the plug is corroded, replace it.


    1. Using a 10 mm hexagon socket wrench, install 4 new gaskets and the 4 straight screw plugs to the exhaust cooler assembly.

      B00481GC02
      *a RH Side *b Upper Side
      *c Lower Side - -
      Torque:
      Straight Screw Plug (A)
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }
      Straight Screw Plug (B)
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  3. INSTALL EXHAUST MANIFOLD TO HEAD GASKET


    1. Install a new exhaust manifold to head gasket to the cylinder head sub-assembly.

  4. INSTALL EXHAUST COOLER ASSEMBLY


    1. B004630E01

      Temporarily install the exhaust cooler assembly to the cylinder head sub-assembly with 4 bolts and 3 new nuts.

      Tech Tips

      Make sure that there is no oil or grease on the threads of the bolts or the bolt holes.

    2. Tighten the 4 bolts and 3 nuts in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  5. CONNECT NO. 7 WATER BY-PASS HOSE


    1. Connect the No. 7 water by-pass hose to the exhaust cooler assembly and slide the hose clip to secure it.

  6. INSTALL GENERATOR ASSEMBLY


  7. INSTALL FAN AND GENERATOR V BELT

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  8. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  9. CONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

    Note

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

    Click here

  10. ADD ENGINE COOLANT

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  11. INSPECT FOR COOLANT LEAK

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  12. INSPECT FOR EXHAUST GAS LEAK

    Tech Tips

    Perform "Inspection After Repairs" after repairing or replacing the exhaust system.

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