EGR COOLER INSTALLATION

PROCEDURE

1. INSTALL NO. 1 EGR COOLER

   
   

   1. Install a new gasket and the No. 1 EGR cooler to the No. 2 EGR valve assembly with electric EGR control valve assembly with the 4 bolts.

      Torque:

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

2. INSTALL NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY

   
   

   1. Temporarily install the No. 1 EGR cooler and No. 2 EGR valve assembly with electric EGR control valve assembly to the intake manifold with the 4 bolts.

   2. 

      Tighten the 4 bolts in the order shown in the illustration.

      Note

      Make sure to tighten the bolts in the order.

      Torque:

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

3. INSTALL VACUUM CONTROL VALVE SET

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4. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

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5. CONNECT NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY

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6. INSTALL NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY

   
   

   1. Install the No. 3 water by-pass pipe sub-assembly to the No. 1 EGR cooler with the 2 bolts.

      Torque:

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

   2. Connect the No. 9 water by-pass hose to the electric EGR control valve assembly, and slide the clamp to secure the hose.

   3. Connect the No. 8 water by-pass hose to the No. 3 water by-pass pipe sub-assembly, and slide the clamp to secure the hose.

   4. Connect the No. 4 fuel hose to the No. 3 water by-pass pipe sub-assembly.

7. INSTALL NO. 2 EGR PIPE

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8. INSTALL EGR VALVE BRACKET

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9. CONNECT ENGINE WIRE

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10. CONNECT FUEL FILTER ASSEMBLY

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11. INSTALL NO. 2 ENGINE COVER BRACKET

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12. INSTALL NO. 2 HOSE TO HOSE TUBE

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13. INSTALL TURBO PRESSURE SENSOR

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14. INSTALL GAS FILTER

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15. INSTALL NO. 2 WATER BY-PASS PIPE

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16. INSTALL DIESEL THROTTLE BODY ASSEMBLY

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17. ADD ENGINE COOLANT

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18. INSPECT FOR COOLANT LEAK

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