EGR VALVE INSTALLATION

PROCEDURE


  1. INSTALL EGR VALVE ASSEMBLY


    1. A003OX1C02
      *a Claw

      Install a new EGR valve gasket to the EGR valve assembly.

      Note

      Make sure that the claws of the EGR valve gasket are toward the EGR valve assembly side.

    2. Set the EGR valve assembly to the EGR pipe with cooler sub-assembly.

    3. Using an E8 "TORX" socket wrench, install the stud bolt to the camshaft housing sub-assembly.

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

      Tech Tips

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

    4. Install the EGR valve assembly to the EGR pipe with cooler sub-assembly with the 3 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    5. A003LFAC01
      *a 0 to 4 mm (0 to 0.157 in.)
      *b Up
      *c LH
      *d 180°

      Connect the water by-pass hose to the EGR valve assembly and slide the clip to secure it.

      Tech Tips

      Engage the clip within the area shown in the illustration.

    6. A003ODJC01
      *a 0 to 4 mm (0 to 0.157 in.)
      *b Up
      *c LH
      *d 180°

      Connect the No. 6 water by-pass hose to the EGR valve assembly and slide the clip to secure it.

      Tech Tips

      Engage the clip within the area shown in the illustration.

    7. Connect the EGR valve assembly connector.

  2. INSTALL EGR PIPE ASSEMBLY

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  3. INSTALL INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulated gloves.

    Note


    • Be careful not to damage the surrounding components when installing the inverter with converter assembly.

    • To prevent damage to the inverter with converter assembly, do not hold the coolant pipe, bracket or connector when securing the inverter with converter assembly.

    • To prevent damage due to static electricity, do not touch the terminals of the inverter with converter assembly connector.

    • Make sure to seal the inverter with converter assembly with the connector cover assembly or tape (non-residue type) etc., until just before installing the inverter with converter assembly to prevent entry of foreign matter and water.


    1. Remove the rope or equivalent that was securing the inverter with converter assembly.

    2. Temporarily install the inverter with converter assembly with the 5 bolts and 2 nuts.

      Note

      Make sure that the inverter with converter assembly is positioned so that the stud bolts are in contact with the base of the U-shaped portions of the No. 1 inverter bracket.

      A003KSIC01
      *a Correct
      *b Incorrect

    3. Tighten the bolt (A).

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      A003K5YC02
      B006IR6 Bolt B006IKP Nut

    4. Tighten the 3 bolts (B).

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

    5. Tighten the bolt (C).

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

    6. Tighten the 2 nuts.

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

  4. CONNECT AIR CONDITIONING WIRE

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  5. CONNECT HV FLOOR UNDER WIRE

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  6. CONNECT ENGINE WIRE (w/o Canister Pump Module)

    CAUTION:

    Wear insulated gloves.

    Note

    Do not allow any foreign matter or water to enter the inverter with converter assembly.


    1. B006H9DE01

      Engage the 4 clamps to connect the engine wire.

    2. Install the 2 bolts (A).

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

    3. Install the bolt (B).

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }
    4. A003MRT

      Move the 2 lock levers as shown in the illustration and connect the 2 inverter with converter assembly connectors.

      Note


      • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.

      • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.

      • Do not allow any foreign matter or water to enter the inverter with converter assembly.

      • Insulate the disconnected terminals with insulating tape.

      • Do not touch the waterproof seal or terminals of the connector.

    5. A003OH5

      Engage the 2 claws.

    6. Connect the 3 No. 1 engine room relay block and No. 1 junction block assembly connectors.

    7. Install the No. 1 relay block cover.

    8. A003MES

      Connect the ECM connector and lower the lever.

      Note


      • When connecting the ECM connector, make sure that the connecting part of the ECM connector is free of dirt, water or other foreign matter.

      • Be sure to securely connect the ECM connector.

  7. CONNECT ENGINE WIRE (w/ Canister Pump Module)

    CAUTION:

    Wear insulated gloves.

    Note

    Do not allow any foreign matter or water to enter the inverter with converter assembly.


    1. A003OKQN01

      Engage the 4 clamps to connect the engine wire.

    2. Install the 2 bolts (A).

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

    3. Install the bolt (B).

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }
    4. A003OGQ

      Move the 2 lock levers as shown in the illustration and connect the 2 inverter with converter assembly connectors.

      Note


      • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.

      • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.

      • Do not allow any foreign matter or water to enter the inverter with converter assembly.

      • Insulate the disconnected terminals with insulating tape.

      • Do not touch the waterproof seal or terminals of the connector.

    5. A003OH5

      Engage the 2 claws.

    6. Connect the 3 No. 1 engine room relay block and No. 1 junction block assembly connectors.

    7. Install the No. 1 relay block cover.

    8. A003MES

      Connect the ECM connector and lower the lever.

      Note


      • When connecting the ECM connector, make sure that the connecting part of the ECM connector is free of dirt, water or other foreign matter.

      • Be sure to securely connect the ECM connector.

  8. INSTALL BATTERY CLAMP SUB-ASSEMBLY

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  9. INSTALL AUXILIARY BATTERY

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  10. CONNECT ENGINE WIRE

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  11. ADD ENGINE COOLANT (for Engine)

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  12. INSPECT FOR COOLANT LEAK (for Engine)

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  13. INSTALL REAR ENGINE UNDER COVER LH

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  14. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

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  15. INSTALL COWL BODY MOUNTING REINFORCEMENT LH

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  16. INSTALL WATER GUARD PLATE

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  17. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)

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

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  19. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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  20. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

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  21. INSTALL SERVICE PLUG GRIP

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