EGR VALVE INSTALLATION

PROCEDURE


  1. INSTALL NO. 2 EGR VALVE ASSEMBLY


    1. Using an E8 "TORX" socket wrench, install the 4 stud bolts to the No. 2 EGR valve assembly.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

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

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

  2. INSTALL EGR VALVE ADAPTER


    1. Install a new gasket and the EGR valve adapter to the No. 2 EGR valve assembly with the 2 bolts.

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

  3. INSTALL NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY


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

    2. B0024UDN01

      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 }

  4. INSTALL VACUUM CONTROL VALVE SET


    1. Install the vacuum control valve set to the intake manifold with the 2 bolts.

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

    2. Connect the 2 vacuum hoses to the No. 2 vacuum transmitting pipe sub-assembly and No. 2 EGR valve assembly.

    3. Install the engine wire bracket with the bolt.

      Torque:
      18.5 N*m  { 189 kgf*cm, 14 ft.*lbf }

  5. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY


    1. Using an E8 "TORX" socket wrench, install 2 new stud bolts to the exhaust manifold.

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

    2. Install 2 new gaskets and the No. 1 EGR pipe sub-assembly to the exhaust manifold and EGR valve adapter with 4 new nuts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

    3. Connect the No. 1 EGR pipe sub-assembly to the vacuum transmitting pipe sub-assembly with the bolt.

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

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


    1. Connect the No. 4 water by-pass pipe sub-assembly to the intake manifold with the 2 bolts.

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

    2. Connect the water hose to the No. 2 EGR valve assembly, and slide the clamp to secure the hose.

    3. Connect the No. 7 water by-pass hose to the No. 1 EGR cooler, and slide the clamp to secure the hose.

  7. 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. 8 water by-pass hose to the No. 3 water by-pass pipe sub-assembly, and slide the clamp to secure the hose.

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

  8. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY


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

      Torque:
      25 N*m  { 255 kgf*cm, 18 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. Attach the clamp and connect the connector to the common rail assembly.

  9. INSTALL NO. 2 EGR PIPE


    1. Install 2 new gaskets and No. 2 EGR pipe to the electric EGR control valve assembly and the intake manifold with the 4 nuts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  10. INSTALL EGR VALVE BRACKET


    1. Install the EGR valve bracket to the electric EGR control valve assembly and intake manifold with the bolt and nut.

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

  11. CONNECT ENGINE WIRE


    1. Connect the connector to the vacuum control valve set.

    2. Attach the clamp and install the bolt.

      Torque:
      18.5 N*m  { 189 kgf*cm, 14 ft.*lbf }

    3. Attach the clamp and connect the connector to the power steering oil pressure switch.

    4. w/o DPF:


      1. Attach the clamp and install the bolt.

        Torque:
        12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

      2. Connect the connector to the sensor wire of the common rail assembly.

      3. Connect the connector to the glow plug connector.

      4. Connect the connector to the electric EGR control valve assembly.

      5. Connect the 4 connectors to the 4 injector assemblies.

      6. Connect the connector to the camshaft position sensor.

    5. w/ DPF:


      1. Attach the 2 clamps and install the bolt.

        Torque:
        12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

      2. Connect the connector to the sensor wire of the common rail assembly.

      3. Connect the connector to the glow plug connector.

      4. Connect the connector to the electric EGR control valve assembly.

      5. Connect the 4 connectors to the 4 injector assemblies.

      6. Connect the connector to the camshaft position sensor.

      7. Connect the connector to the exhaust fuel addition injector assembly.

      8. Connect the 3 connectors to the 3 exhaust gas temperature sensors.

      9. Connect the connector to the differential pressure sensor.

    6. Attach the 2 clamps and connect the 2 connectors to the turbocharger sub-assembly.

  12. CONNECT FUEL FILTER ASSEMBLY


    1. Connect the fuel filter assembly to the fuel filter support.

    2. B0024VJN01

      Attach the clamp and slide the lead wire as shown in the illustration to install it.

  13. INSTALL NO. 2 ENGINE COVER BRACKET


    1. Install the No. 2 engine cover bracket to the No. 3 water by-pass pipe sub-assembly and No. 2 EGR valve assembly with the 2 bolts.

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

  14. INSTALL NO. 2 HOSE TO HOSE TUBE


    1. Install the No. 2 hose to hose tube to the cylinder head cover sub-assembly and hose bracket with the 2 bolts.

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

    2. Connect the union to check valve hose to the vacuum pump assembly, and slide the clamp to secure the hose.

    3. Connect the union to connector tube hose to the No. 1 hose to hose tube, and slide the clamp to secure the hose.

  15. INSTALL TURBO PRESSURE SENSOR


    1. Install the turbo pressure sensor to the No. 3 water by-pass pipe sub-assembly with the bolt.

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

    2. Connect the connector to the turbo pressure sensor.

  16. INSTALL GAS FILTER


    1. Install the gas filter to the gas filter bracket.

    2. Connect the 2 vacuum hoses to the turbo pressure sensor and intake manifold.

  17. INSTALL NO. 2 WATER BY-PASS PIPE


    1. Install the No. 2 water by-pass pipe to the cylinder head cover sub-assembly, No. 3 water by-pass pipe sub-assembly and No. 2 engine cover bracket with the 4 bolts.

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

    2. Connect the No. 16 water by-pass hose to the No. 1 EGR cooler, and slide the clamp to secure the hose.

    3. Connect the 2 heater hoses to the No. 2 water by-pass pipe, and slide the 2 clamps to secure the 2 hoses.

    4. Connect the No. 15 water by-pass hose to the water by-pass pipe, and slide the clamp to secure the hose.

    5. w/o Viscous Heater:

      Connect the No. 2 water by-pass pipe to the No. 13 water by-pass hose, and slide the clamp to secure the hose.

    6. w/ Viscous Heater:

      Connect the No. 2 water by-pass pipe to the water hose sub-assembly, and slide the clamp to secure the hose.

  18. INSTALL DIESEL THROTTLE BODY ASSEMBLY

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  19. ADD ENGINE COOLANT

    Click here

  20. INSPECT FOR COOLANT LEAK

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