EGR COOLER INSTALLATION


  1. INSTALL NO. 2 EGR VALVE ASSEMBLY


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

      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.

    2. Temporarily install the No. 1 EGR pipe 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, No. 2 EGR valve and EGR cooler.

  3. INSTALL EGR COOLER WITH PIPE ASSEMBLY


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

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

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

      A00OQY1E01
      Text in Illustration
      *1 Nut - -
      Bolt Length
      Item Specified Condition
      Bolt A 16 mm (0.630 in.)
      Bolt B 16 mm (0.630 in.)
      Bolt C 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 hose.

  4. INSTALL NO. 2 WATER BY-PASS HOSE

  5. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY