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

  2. INSTALL EGR PIPE CONNECTOR


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

    2. Install a new gasket and EGR pipe connector with the bolt and 2 nuts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  3. INSTALL EGR PIPE WITH COOLER SUB-ASSEMBLY


    1. Install 2 new gaskets to the cylinder head and EGR valve (electric EGR control valve assembly).

    2. Install the EGR pipe with cooler sub-assembly with the 4 bolts and 2 nuts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
    3. A012HYJC01
      *a View A
      *b Front Side

      Connect the No. 2 oil cooler hose and No. 2 water by-pass hose to the EGR pipe with cooler sub-assembly, and slide the 2 clips to secure them.

      Note

      Engage the clip within the area shown in the illustration.

    4. Connect the vacuum hose to the No. 2 EGR valve assembly.

    5. Install the manifold absolute pressure sensor (diesel turbo pressure sensor) with the bolt and connect the vacuum transmitting hose.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
    6. A012IG3

      Connect the 2 connectors and install the bolt.

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

    7. Connect the connector and engage the wire harness clamp.

  4. INSTALL EGR BYPASS VALVE SWITCHING VALVE (NO. 1 VACUUM SWITCHING VALVE ASSEMBLY)

    Click here

  5. ADD ENGINE COOLANT

    Click here

  6. INSPECT FOR COOLANT LEAK

    Click here

  7. INSPECT FOR EXHAUST GAS LEAK

  8. INSTALL NO. 1 ENGINE COVER (w/ No. 1 Engine Cover)

    Click here