EGR COOLER INSTALLATION

PROCEDURE


  1. INSTALL EGR PIPE WITH COOLER SUB-ASSEMBLY


    1. A003OKB

      Using an E8 "TORX" socket wrench, install the 3 stud bolts to the EGR pipe with cooler sub-assembly.

      Tech Tips

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

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

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

    3. Install the EGR pipe with cooler sub-assembly to the EGR valve assembly with the 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. A003KNBC01
      *a 7 to 11 mm (0.276 to 0.433 in.)
      *b LH
      *c Front of the vehicle
      *d 180°

      Connect the No. 6 water by-pass hose to the EGR pipe with cooler sub-assembly and slide the clip to secure it.

      Tech Tips

      Engage the clip within the area shown in the illustration.

    5. Install a new EGR cooler gasket to the EGR pipe with cooler sub-assembly.

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

    7. A003MEYC01
      *a Stud Bolt (A)
      *b Stud Bolt (B)
      *c 48 mm (1.890 in.)
      *d 26 mm (1.024 in.)
      *e 13 mm (0.512 in.)
      *f 29 mm (1.142 in.)
      *g 14 mm (0.551 in.)
      *h 13 mm (0.512 in.)

      Using an E8 "TORX" socket wrench, install the stud bolt (A) and stud bolt (B) to the cylinder head sub-assembly and camshaft housing sub-assembly.

      Tech Tips

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

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }
    8. A003KATC01
      B006IR6 Bolt
      B006IKP Nut

      Temporarily install the EGR pipe with cooler sub-assembly with the EGR valve assembly to the cylinder head sub-assembly and camshaft housing sub-assembly with the bolt and 2 nuts.

    9. A003MPE

      Temporarily install the EGR pipe with cooler sub-assembly to the exhaust manifold (TWC: Front Catalyst) with 2 new nuts.

    10. Tighten the bolt and 2 nuts.

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

    11. Tighten the 2 nuts.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

    12. Connect the EGR valve assembly connector.

  2. CONNECT NO. 4 WATER BY-PASS HOSE


    1. A003LJXC01
      *a Up
      *b LH
      *c Paint Mark
      *d 180°

      Connect the No. 4 water by-pass hose to the EGR pipe with cooler sub-assembly and slide the clip to secure it.

      Tech Tips

      Engage the clip within the area shown in the illustration.

  3. CONNECT INLET HEATER WATER HOSE A


    1. A003M6KC01
      *a Up
      *b LH
      *c Paint Mark
      *d 120°

      Connect the inlet heater water hose A to the EGR pipe with cooler sub-assembly and slide the clip to secure it.

      Tech Tips

      Engage the clip within the area shown in the illustration.

  4. CONNECT WATER BY-PASS HOSE


    1. A003N87C01
      *a Up
      *b LH
      *c Paint Mark
      *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.

  5. INSTALL EGR PIPE ASSEMBLY

    Click here

  6. INSTALL FLOW SHUTTING VALVE (WATER VALVE) (w/ Flow Shutting Valve (Water Valve))

    Click here

  7. INSTALL INVERTER WITH CONVERTER ASSEMBLY

    Click here

  8. ADD ENGINE COOLANT (for Engine)

    Click here

  9. INSPECT FOR COOLANT LEAK (for Engine)

    Click here

  10. INSPECT FOR EXHAUST GAS LEAK

    Click here