EGR COOLER INSTALLATION

PROCEDURE


  1. INSTALL EGR WITH COOLER PIPE SUB-ASSEMBLY


    1. A004Z6K

      Temporarily install a new gasket and the EGR valve assembly to the EGR with cooler pipe sub-assembly with the 2 nuts.

    2. Install 2 new gaskets and set the EGR valve with cooler assembly in place.

    3. Using an E8 "TORX" socket wrench, install the 4 stud bolts.

      A00509EE04
      Text in Illustration
      *a Stud Bolt A *b Stud Bolt B
      *c Stud Bolt C - -
      Torque:
      Stud Bolt (A) and Stud Bolt (B)
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }
      Stud Bolt (C)
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

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

    4. Temporarily install the 2 nuts (B), 2 nuts (C) and bolt.

      Tech Tips

      Type B and type C of the nut (C) are non-reusable.

      A0050COE02
      Text in Illustration
      *A Type A *B Type B
      *C Type C - -
      *a Nut A *b Nut B
      *c Nut C *d Bolt

    5. Tighten the 2 nuts (A).

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

    6. Tighten the 2 nuts (B) and bolt.

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

      Note

      Make sure that all installation surfaces of the EGR valve with cooler assembly are in even contact when tightening the bolt and nuts.

    7. Tighten the 2 nuts (C).

      Torque:
      Type A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Type B
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
      Type C
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }
    8. A004Y8S

      Connect the 4 water hoses to the EGR valve with cooler assembly and slide the 4 clips to secure them.

    9. Engage the wire harness clamp.

    10. Connect the EGR valve assembly connector.

  2. INSTALL EGR PIPE ASSEMBLY

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  3. INSTALL AIR CLEANER CASE

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  4. INSTALL INLET AIR CLEANER ASSEMBLY

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  5. INSTALL WATER HOSE HOSE CLAMP

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  6. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

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  7. INSTALL NO. 2 CYLINDER HEAD COVER

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  8. ADD COOLANT (for Engine)

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  9. INSPECT FOR COOLANT LEAK (for Engine)

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  10. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)

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  11. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)

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  12. INSTALL COWL BODY MOUNTING REINFORCEMENT LH (for LHD)

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  13. INSTALL COWL BODY MOUNTING REINFORCEMENT RH (for RHD)

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  14. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)

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  15. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

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  16. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)

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  17. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

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  18. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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