EGR VALVE INSTALLATION

PROCEDURE


  1. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the wire harness clamp bracket with the bolt.

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

  2. INSTALL EGR VALVE ASSEMBLY


    1. A01KRQN

      Temporarily install a new EGR valve gasket and the EGR valve assembly to the EGR cooler assembly with the 2 nuts.

    2. Install a new EGR cooler gasket and set the EGR valve with cooler assembly in place.

    3. Using an E8 "TORX" socket wrench, install the 4 stud bolts.

      A01KRJCC02
      *a Stud Bolt A *b Stud Bolt B
      *c Stud Bolt C - -
      Torque:
      Stud Bolt A and Stud Bolt B
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }
      Stud Bolt C
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Tech Tips

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

    4. Temporarily install the 2 nuts (B), 2 nuts (C) and bolt.

      Tech Tips

      The type B nut and type C nut are non-reusable.

      A01KRPUC03
      *A Type A *B Type B
      *C Type C - -
      *a Nut A *b Nut B
      *c Nut C *d Bolt
      *e 18 mm (0.709 in.) *f 17 mm (0.669 in.)

    5. Tighten the 2 nuts (A).

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

    6. Tighten the 2 nuts (B) and bolt.

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

      Note

      Make sure that all installation surfaces of the EGR valve with cooler assembly are in even contact when tightening the bolt and nuts.

    7. Tighten the 2 nuts (C).

      Torque:
      Type A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Type B
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
      Type C
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }
    8. A01KTVM

      Connect the connector and engage the wire harness clamp.

    9. Connect the 4 water hoses and slide the 4 clips to secure them.

  3. INSTALL EGR PIPE ASSEMBLY


    1. Install a new EGR pipe gasket, EGR inlet gasket and the EGR pipe assembly with the 4 bolts.

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

      Note

      Make sure to tighten the 4 bolts evenly until the flanges of the EGR pipe assembly contact with the installation surfaces.

    2. Install the wire harness support with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    3. A01KT5S

      Engage the 2 wire harness clamps.

  4. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

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  5. INSTALL INLET AIR CLEANER ASSEMBLY

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  6. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

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  7. INSTALL NO. 2 CYLINDER HEAD COVER

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  8. ADD ENGINE COOLANT (for Engine)

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  9. INSPECT FOR COOLANT LEAK (for Engine)

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  10. INSTALL OUTER COWL TOP PANEL (for LHD)

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  11. INSTALL OUTER COWL TOP PANEL (for RHD)

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  12. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)

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  13. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

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  14. INSTALL WATER GUARD PLATE LH (for LHD)

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  15. INSTALL WATER GUARD PLATE LH (for RHD)

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  16. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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