EGR VALVE INSTALLATION

CAUTION / NOTICE / HINT

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

PROCEDURE


  1. INSTALL NO. 2 EGR VALVE ASSEMBLY (w/ EGR Cooler)


    1. Using a 6 mm hexagon wrench, install the EGR valve adapter, No. 2 EGR valve, EGR cooler, 2 new gaskets, 3 plate washers with the 3 hexagon bolts.

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

    2. Using a 5 mm hexagon wrench, install the bolt labeled A.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      B001EDDE01
      Text in Illustration
      *1 EGR Cooler with Pipe *2 New Gasket
      *3 No. 2 EGR Valve *4 EGR Valve Adapter

  2. INSTALL EGR COOLER WITH PIPE (w/ EGR Cooler)


    1. Install a new gasket and the EGR cooler with pipe to the electric EGR control valve and No. 2 EGR valve with the 2 bolts.

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

      Tech Tips

      Make sure the claws of the gasket face the electric EGR control valve.

      B001FT4E01
      Text in Illustration
      *1 EGR Cooler with Pipe and No. 2 EGR Valve *2 New Gasket
      *3 Electric EGR Control Valve - -

  3. TEMPORARILY INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR Cooler)


    1. Place a new gasket, the electric EGR control valve, another new gasket and the intake air connector onto the stud bolts of the No. 2 intake air connector and temporarily install the 3 nuts.

      Note

      Temporarily install the nuts so that 0 to 2 threads of each stud bolt are visible as shown in the illustration.

      B001DJVE01
      Text in Illustration
      *1 No. 2 Intake Air Connector *2 Electric EGR Control Valve
      *3 Intake Air Connector *4 New Gasket
      *a 0 to 2 threads - -

    2. Set a new gasket on the intake manifold.

      Tech Tips

      Make sure the claws of the gasket face the intake manifold.

    3. Temporarily install the intake air connector to the intake manifold with the 3 bolts in the illustration.

    4. Temporarily install the EGR cooler with pipe and new gasket to the cylinder head with the bolt and 2 nuts.

      B001EI1E01
      Text in Illustration
      *1 Electric EGR Control Valve *2 New Gasket

    5. Connect the No. 2 vacuum transmitting hose to the No. 2 EGR valve.

  4. TIGHTEN ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR Cooler)


    1. Tighten the 3 nuts labeled A in the illustration.

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

    2. Tighten the 3 bolts labeled B in the illustration.

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

      Note

      Tighten the bolts in the order shown in the illustration.

    3. Tighten the bolt labeled C in the illustration.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

    4. Tighten the 2 nuts labeled D in the illustration.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      B001DDIE01
      Text in Illustration
      *a Front - -

  5. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY (w/o EGR Cooler)


    1. Install a new gasket and the No. 1 EGR pipe to the electric EGR control valve with the 2 bolts.

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

      Tech Tips

      Make sure the claws of the gasket face the electric EGR control valve.

      B001CXME01
      Text in Illustration
      *1 Electric EGR Control Valve *2 New Gasket
      *3 No. 1 EGR Pipe - -

  6. TEMPORARILY INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/o EGR Cooler)


    1. Place a new gasket, the electric EGR control valve, another new gasket and the intake air connector onto the stud bolts of the No. 2 intake air connector and temporarily install the 3 nuts.

      Note

      Temporarily install the nuts so that 0 to 2 threads of each stud bolt are visible as shown in the illustration.

      B001IJDE01
      Text in Illustration
      *1 No. 2 Intake Air Connector *2 Electric EGR Control Valve
      *3 Intake Air Connector *4 New Gasket
      *a 0 to 2 threads - -

    2. Set a new gasket on the intake manifold.

      Tech Tips

      Make sure the claws of the gasket face the intake manifold.

    3. Temporarily install the intake air connector to the intake manifold with the 3 bolts.

    4. Temporarily install the No. 1 EGR pipe and a new gasket to the cylinder head with the 2 nuts.

      B001E4TE01
      Text in Illustration
      *1 Electric EGR Control Valve *2 New Gasket

  7. TIGHTEN ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/o EGR Cooler)


    1. Tighten the 3 nuts labeled A in the illustration.

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

    2. Tighten the 3 bolts labeled B in the illustration.

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

      Note

      Tighten the bolts in the order shown in the illustration.

    3. Tighten the 2 nuts labeled C in the illustration.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      B001CDZE01
      Text in Illustration
      *a Front - -

  8. INSTALL AIR CONNECTOR STAY


    1. B001GOGE01

      Temporarily install the air connector stay with the 3 bolts.

    2. Tighten the bolt labeled A.

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

    3. Tighten the 2 bolts labeled B.

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

  9. INSTALL ELECTRIC VACUUM REGULATING VALVE ASSEMBLY


    1. Install the E-VRV bracket with the 2 bolts.

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

    2. Install the gas filter and the gas filter bracket with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    3. B001GPLE01
      Text in Illustration
      *1 Yellow Mark
      *2 Pink Mark

      Connect the 5 vacuum hoses.

      Note

      Install the vacuum hoses so that they completely cover the pipes.

    4. Connect the 2 connectors to the electric EGR control valve and E-VRV.

    5. Attach the wire harness clamp.

  10. INSTALL EGR VALVE BRACKET


    1. Install the EGR valve bracket with the 2 nuts.

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

  11. CONNECT ENGINE WIRE (for LHD)


    1. B001CC8E01

      Attach the clamp.

    2. Connect the engine wire with the 2 bolts.

      Torque:
      for bolt A
      13 N*m  { 131 kgf*cm, 9 ft.*lbf }
      for bolt B
      22 N*m  { 220 kgf*cm, 16 ft.*lbf }

  12. CONNECT ENGINE WIRE (for RHD)


    1. Connect the engine wire with the bolt.

      Torque:
      13 N*m  { 131 kgf*cm, 9 ft.*lbf }

  13. INSTALL INJECTION PIPE

    Note


    • When replacing an injector, it is necessary to replace the 4 injection pipes with new ones.

    • Keep the joints of the injection pipe clean.


    1. B001GHME01
      Text in Illustration
      *1 No. 2 Injection Pipe

      Temporarily install the No. 1, No. 2 and No. 3 injection pipes with the union nuts.

    2. Install the No. 2 and No. 3 injection pipe clamps with the 2 bolts and 2 nuts as shown in the illustration.

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

      Tech Tips

      If the painted mark on the No. 2 injection pipe has disappeared, use the illustration as a reference to install the clamps.

    3. B001I04E01
      *a for Common Rail Side
      *b for Injector Side

      Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the common rail side.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Note

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

    4. Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the injector side.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Note

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

  14. CONNECT NO. 4 WATER BY-PASS HOSE (w/ EGR Cooler)


    1. B001FPQE01
      Text in Illustration
      *1 Lower Side
      *2 Upper Side
      *3 LH Side of Vehicle

      Connect the No. 4 water by-pass hose to the EGR cooler.

      Tech Tips


      • The direction of the hose clamp is indicated in the illustration.

      • Insert the outlet hose into the stopper.

  15. CONNECT NO. 3 WATER BY-PASS HOSE (w/ EGR Cooler)


    1. Connect the No. 3 water by-pass hose to the EGR cooler.

      Tech Tips


      • The direction of the hose clamp is indicated in the illustration.

      • Insert the outlet hose into the stopper.

    2. Install the clamp.

  16. INSTALL DIESEL THROTTLE BODY ASSEMBLY


    1. Install the diesel throttle body Click here.

  17. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. Install the cowl top ventilator louver Click here.

  18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  19. ADD ENGINE COOLANT (w/ EGR Cooler)

    Click here

  20. INSPECT FOR COOLANT LEAK (w/ EGR Cooler)

    Click here

  21. BLEED AIR FROM FUEL SYSTEM

    Click here

  22. INSPECT FOR FUEL LEAK

    Click here

  23. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

    Click here

  24. INSTALL FRONT BUMPER LOWER COVER

    Click here