EGR VALVE INSTALLATION
CAUTION / NOTICE / HINT
Note
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When replacing the injectors (including shuffling the injectors between the cylinders), common rail, cylinder head, or intake manifold, it is necessary to replace the injection pipes with new ones.
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w/ DPF:
When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines Click here.
PROCEDURE
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INSTALL EGR COOLER GASKET
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Install a new gasket.
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INSTALL NO. 2 EGR VALVE ASSEMBLY
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INSTALL NO. 1 EGR VALVE ASSEMBLY
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INSTALL NO. 9 WATER BY-PASS HOSE AND WATER HOSE
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Connect the 2 water hoses.
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Install the No. 9 water by-pass hose.
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INSTALL NO. 3 EGR PIPE
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w/ DPF:
Install a new O-ring to the No. 3 water by-pass pipe.
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Install 2 new gaskets.
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Install the No. 3 EGR pipe with the 4 nuts and 4 bolts.
- Torque:
- 21 N*m { 214 kgf*cm, 15 ft.*lbf }
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INSTALL EGR VALVE ASSEMBLY WITH EGR COOLER
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Install the EGR valve with EGR cooler with the 6 bolts.
- Torque:
- 21 N*m { 214 kgf*cm, 15 ft.*lbf }
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INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY
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Install 2 new gaskets to the No. 2 EGR pipe.
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Install the No. 2 EGR pipe with the 4 bolts.
- Torque:
- 29 N*m { 296 kgf*cm, 21 ft.*lbf }
Note
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Press down the cooler side by hand while tightening the bolts on the cylinder head side.
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If the insulator installation stay is deformed, replace the No. 2 EGR pipe.
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If the clearance between the head and flange is 1 mm (0.0394 in.) or more, replace the No. 2 EGR pipe.
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INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY
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Install 2 new gaskets to the No. 1 EGR pipe.
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Install the No. 1 EGR pipe with the 4 bolts.
- Torque:
- 29 N*m { 296 kgf*cm, 21 ft.*lbf }
Note
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Press down the cooler side by hand while tightening the bolts on the cylinder head side.
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If the insulator installation stay is deformed, replace the No. 1 EGR pipe.
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If the clearance between the head and flange is 1 mm (0.0394 in.) or more, replace the No. 1 EGR pipe.
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CONNECT NO. 5 WATER BY-PASS PIPE
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Connect the 2 hoses and install the bolt to connect the No. 5 water by-pass pipe.
- Torque:
- 10 N*m { 102 kgf*cm, 7 ft.*lbf }
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INSTALL EGR PIPE INSULATOR
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INSTALL INTAKE MANIFOLD INSULATOR
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INSTALL NO. 3 INTAKE MANIFOLD
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CONNECT NO. 2 ENGINE WIRE
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INSTALL INTAKE PIPE
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Install a new gasket.
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Install the intake pipe with the 4 bolts and 2 nuts.
- Torque:
- 21 N*m { 214 kgf*cm, 15 ft.*lbf }
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INSTALL NO. 4 EGR PIPE
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Install 2 new gaskets to the No. 4 EGR pipe.
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Install the No. 4 EGR pipe with the 4 bolts.
- Torque:
- 21 N*m { 214 kgf*cm, 15 ft.*lbf }
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INSTALL NO. 2 INTAKE MANIFOLD INSULATOR
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INSTALL NO. 1 INTAKE MANIFOLD INSULATOR
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INSTALL NO. 3 NOZZLE LEAKAGE PIPE (w/ DPF)
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INSTALL COMMON RAIL ASSEMBLY RH
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INSTALL INJECTION PIPE RH
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INSTALL CYLINDER HEAD COVER SILENCER RH (w/ DPF)
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INSTALL NO. 5 INJECTION PIPE SUB-ASSEMBLY
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CONNECT FUEL PUMP MOTOR WIRE
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INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY
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INSTALL COMMON RAIL ASSEMBLY LH
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INSTALL NO. 5 NOZZLE LEAKAGE PIPE (w/ DPF)
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INSTALL NO. 2 FUEL PIPE (w/ DPF)
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CONNECT CONNECTING WIRE (w/ DPF)
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INSTALL INJECTION PIPE LH
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INSTALL NO. 4 NOZZLE LEAKAGE PIPE (w/ DPF)
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INSTALL CYLINDER HEAD COVER SILENCER LH (w/ DPF)
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INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ DPF)
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INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (w/ DPF)
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INSTALL NO. 6 INJECTION PIPE SUB-ASSEMBLY
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INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY (w/o DPF)
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CONNECT ENGINE WIRE
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INSTALL NO. 4 WATER BY-PASS PIPE
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INSTALL NO. 3 WATER BY-PASS PIPE (w/o Viscous Heater)
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CONNECT FUEL HOSE
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INSTALL NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY
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INSTALL HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)
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INSTALL NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY
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INSTALL NO. 4 AIR TUBE
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INSTALL NO. 2 AIR HOSE
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INSTALL NO. 3 AIR TUBE
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INSTALL NO. 1 AIR HOSE
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INSTALL INTAKE AIR CONNECTOR
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TEMPORARILY INSTALL NO. 1 AIR CLEANER HOSE
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INSTALL AIR CLEANER CAP SUB-ASSEMBLY
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INSTALL DIESEL THROTTLE BODY ASSEMBLY LH
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INSTALL NO. 3 INTERCOOLER SUPPORT BRACKET
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Install the No. 3 intercooler support bracket with the 2 bolts.
- Torque:
- 21 N*m { 214 kgf*cm, 15 ft.*lbf }
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for Manual Transmission:
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Connect the clutch tube to release cylinder 2 way with the bolt.
- Torque:
- 20 N*m { 204 kgf*cm, 15 ft.*lbf }
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Check that the union nut is tightened to the specified torque.
- Torque:
- 15 N*m { 154 kgf*cm, 11 ft.*lbf }
Tech Tips
Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.
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INSTALL NO. 1 GAS FILTER
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Install the No. 1 gas filter.
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Connect the hose to the intake pipe.
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INSTALL TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for Manual Transmission)
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INSTALL AIR TUBE SUB-ASSEMBLY LH
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INSTALL CLUTCH HOSE (for Manual Transmission)
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INSTALL DIESEL THROTTLE BODY ASSEMBLY RH
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INSTALL AIR TUBE SUB-ASSEMBLY RH
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INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE
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CONNECT WATER HOSE SUB-ASSEMBLY
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INSTALL INTERCOOLER ASSEMBLY
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CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Note
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
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Connect the cables to the negative (-) main battery and sub-battery terminals.
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ADD ENGINE COOLANT
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ADD CLUTCH FLUID
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FILL BRAKE FLUID RESERVOIR (for Manual Transmission)
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BLEED CLUTCH LINE (for Manual Transmission)
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CHECK FLUID LEVEL IN RESERVOIR (for Manual Transmission)
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INSPECT FOR CLUTCH FLUID LEAK (for Manual Transmission)
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BLEED AIR FROM FUEL SYSTEM
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INSPECT FOR FUEL LEAK
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INSPECT FOR COOLANT LEAK
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INSPECT FOR OIL LEAK
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INSTALL UPPER RADIATOR SUPPORT SEAL
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INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY
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INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH
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INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH
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PERFORM ELECTRIC EGR CONTROL VALVE COMPENSATION RESET