EGR COOLER INSTALLATION

PROCEDURE


  1. INSTALL STUD BOLT

    Tech Tips

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


    1. Using an E8 "TORX" socket wrench, install the 2 stud bolts to the EGR pipe with cooler sub-assembly.

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

  2. INSTALL NO. 2 EGR VALVE ASSEMBLY


    1. Install a new gasket and the No. 2 EGR valve assembly to the EGR pipe with cooler sub-assembly.

      Tech Tips

      Make sure that the claw of the gasket is facing the EGR pipe with cooler sub-assembly.

  3. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY


    1. Install a new gasket to the No. 2 EGR valve assembly.

    2. Temporarily install the No. 1 EGR pipe sub-assembly with the 2 bolts and 2 nuts.

      Tech Tips

      Tighten the bolts and nuts until there is no gap between the No. 1 EGR pipe sub-assembly, No. 2 EGR valve assembly and EGR pipe with cooler sub-assembly.

  4. INSTALL EGR PIPE WITH COOLER SUB-ASSEMBLY


    1. Install a new O-ring to the EGR pipe with cooler sub-assembly.

    2. Install a new gasket to the EGR pipe with cooler sub-assembly and a new gasket to the No. 1 EGR pipe sub-assembly.

    3. Temporarily install the EGR pipe with cooler sub-assembly with the 6 bolts and 2 nuts.

      A012JDWC01
      *1 16 mm
      *2 25 mm
      A012M0O Bolt A012L0C Nut
      Bolt Length
      Item Specified Condition
      Bolt A 16 mm (0.630 in.)
      Bolt B 16 mm (0.630 in.)
      Bolt C 25 mm (0.984 in.)

    4. Tighten the 2 bolts (A) and 2 nuts (A) shown in the illustration.

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

    5. Tighten the 2 bolts (B) shown in the illustration.

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

    6. Tighten the 2 bolts (C) shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    7. Tighten the 2 bolts (D) and 2 nuts (D) shown in the illustration.

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

    8. Connect the vacuum hose.

  5. INSTALL NO. 2 WATER BY-PASS HOSE


    1. Install the No. 2 water by-pass hose, and slide the 2 clips to secure it.

  6. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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