EGR COOLER INSTALLATION

PROCEDURE


  1. INSTALL NO. 2 EGR VALVE ASSEMBLY


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

      Tech Tips

      Make sure that the claw of the gasket faces the EGR cooler.

  2. 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 cooler.

  3. INSTALL EGR COOLER WITH PIPE ASSEMBLY


    1. Install a new O-ring to the EGR cooler.

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

    3. Temporarily install the EGR cooler with pipe assembly with the 6 bolts and 2 nuts labeled A, B and C.

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      *1 Nut - -
      *a 16 mm (0.630 in.) *b 25 mm (0.984 in.)

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

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

    5. Tighten the 2 bolts labeled B shown in the illustration.

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

    6. Tighten the 2 bolts labeled C shown in the illustration.

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

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

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

    8. Connect the vacuum transmitting hose to the No. 2 EGR valve assembly.

  4. INSTALL NO. 2 WATER BY-PASS HOSE


    1. Install the No. 2 water by-pass hose to the turbo oil outlet pipe and EGR cooler, and slide the 2 clamps to secure the hose.

  5. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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