EGR VALVE (w/o DPF) INSTALLATION


  1. INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY


    1. Install a new gasket and the No. 2 EGR pipe with the 2 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  2. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. Install the vacuum regulating valve with the 2 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Install a new gasket and the electric EGR valve to the intake air connector.

    3. Install 2 new gaskets and the electric EGR valve together with the intake air connector to the intake manifold with the bolt and 2 nuts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    4. Connect the 2 vacuum hoses to the vacuum regulating valve.

    5. Connect the vacuum regulating valve connector.

  3. INSTALL MANIFOLD STAY


    1. Install the manifold stay with the 2 bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  4. INSTALL INTAKE AIR TEMPERATURE SENSOR


    1. Install a new gasket to the intake air temperature sensor.

    2. Using a 22 mm ball joint lock nut wrench, install the intake air temperature sensor.

      Torque:
      34 N*m  { 350 kgf*cm, 25 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a ball joint lock nut wrench is combined with a torque wrench Click here.

    3. Connect the intake air temperature sensor connector.

  5. INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. Install the manifold absolute pressure sensor with the 2 bolts and connect the vacuum hose.

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

  6. INSTALL VACUUM SWITCHING VALVE ASSEMBLY


    1. Install the vacuum switching valve with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Connect the connector and vacuum hose to the vacuum switching valve.

    3. Attach the clamp and wire harness.

    4. Connect the connector to the electric EGR control valve.

  7. CONNECT NO. 1 GAS FILTER


    1. Connect the vacuum hose together with the gas filter.

    2. Install the bolt.

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

  8. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring to the engine oil level dipstick guide.

    2. Apply a small amount of clean engine oil to the O-ring.

    3. Install the engine oil level dipstick guide with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 72 in.*lbf }

  9. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY (for Automatic Transmission)


    1. A003D9DE03

      Coat a new O-ring with ATF and install it onto the oil filler tube sub-assembly.

    2. Install the oil filler tube sub-assembly with the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  10. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Click here

  11. INSPECT FOR EXHAUST GAS LEAK

    If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

  12. INSTALL NO. 2 ENGINE SERVICE HOLE COVER (for Standard Body)


    1. Install the No. 2 engine service hole cover with the 3 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    2. Return the carpet to its original position and attach the clips.

  13. INSTALL NO. 2 ENGINE UNDER COVER (for Cold Area Specification Vehicles)


    1. Install the No. 2 engine under cover with the 6 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  14. INSTALL NO. 1 ENGINE UNDER COVER (for Cold Area Specification Vehicles)


    1. Install the No. 1 engine under cover with the 4 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }