EGR COOLER INSTALLATION

PROCEDURE


  1. INSTALL EGR VALVE ASSEMBLY

    Click here

  2. INSTALL EGR COOLER ASSEMBLY


    1. Install the EGR cooler assembly to the cylinder head sub-assembly with the 2 nuts and bolt.

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

    2. Connect the No. 4 water by-pass hose to the EGR valve assembly and slide the clip to secure the hose.

    3. Connect the No. 12 water by-pass hose to the EGR valve assembly and slide the clip to secure the hose.

    4. Connect the No. 5 water by-pass hose to the EGR cooler assembly and slide the clip to secure the hose.

    5. Connect the No. 6 water by-pass hose to the EGR cooler assembly and slide the clip to secure the hose.

  3. INSTALL EGR VALVE BRACKET


    1. A000NYLE02

      Temporarily install the EGR valve bracket to the EGR valve assembly and cylinder head sub-assembly with the 2 bolts.

      Tech Tips

      Tighten the bolts until they are seated on the EGR valve bracket.

    2. Tighten the 2 bolts in the order shown in the illustration.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

  4. INSTALL NO. 2 EGR PIPE


    1. A000T6NE02
      Text in Illustration
      *1 No. 2 EGR Pipe Gasket
      *a Claws
      B002B6O Nut
      B002BBR Bolt

      Install a new No. 2 EGR pipe gasket to the No. 2 EGR pipe as shown in the illustration.

      Note

      Make sure that the gasket is installed in the correct direction.

    2. Install a new EGR inlet gasket to the intake manifold.

    3. Temporarily install the No. 2 EGR pipe to the EGR valve assembly and intake manifold with the 2 bolts and 2 nuts.

      Tech Tips

      Tighten the bolts and nuts until they are seated on the No. 2 EGR pipe.

    4. Tighten the 2 nuts while pressing the No. 2 EGR pipe against the EGR valve assembly side.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    5. Tighten the 2 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  5. INSTALL ENGINE MOTOR CABLE CLAMP BRACKET


    1. A000R5ME02

      for RHD:

      Install the engine motor cable clamp bracket to the EGR cooler assembly and cylinder head sub-assembly with the 2 bolts in the order shown in the illustration.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    2. for LHD:

      Install the engine motor cable clamp bracket to the EGR cooler assembly with the bolt.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

  6. INSTALL ENGINE ASSEMBLY

    Click here