EGR COOLER INSTALLATION

PROCEDURE


  1. INSTALL EGR COOLER ASSEMBLY


    1. Using an E8 "TORX" socket wrench, install the 2 stud bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    2. Install a new gasket and the EGR valve assembly with the 2 bolts.

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

    3. Connect the No. 1 water by-pass hose.

    4. Temporarily install a new gasket and the EGR valve with cooler assembly with the 2 bolts and 2 nuts.

    5. Install the EGR valve bracket with the 2 bolts and nut.

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

    6. Install the EGR valve with cooler assembly with the 2 bolts and 2 nuts.

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

      Note

      Make sure that all installation surfaces of the EGR valve with cooler assembly are in even contact when tightening the bolts and nuts.

    7. Using an E8 "TORX" socket wrench, install the stud bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
    8. A01UXZ9E01
      Text in Illustration
      *a 2 to 6 mm (0.079 to 0.276 in.)
      *b Up
      *c 90°
      *d Engine Rear

      Connect the No. 4 water by-pass hose and No. 5 water by-pass hose.

    9. Install the wire harness clamp bracket with the bolt.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }
    10. A01UZ6A

      Connect the 2 connectors and wire harness clamp.

  2. INSTALL NO. 2 EGR PIPE

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  3. ADD COOLANT (for Engine)

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  4. INSPECT FOR COOLANT LEAK (for Engine)

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  5. INSTALL OUTER COWL TOP PANEL (for LHD)

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  6. INSTALL OUTER COWL TOP PANEL (for RHD)

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  7. INSTALL INNER COWL TOP TO COWL BRACE (for LHD)

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  8. INSTALL INNER COWL TOP TO COWL BRACE (for RHD)

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  9. INSTALL FRONT NO. 1 VENTILATOR SEAL (for LHD)

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  10. INSTALL FRONT NO. 1 VENTILATOR SEAL (for RHD)

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  11. INSTALL FRONT AIR SHUTTER SEAL RH (for LHD)

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  12. INSTALL FRONT AIR SHUTTER SEAL RH (for RHD)

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  13. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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  14. INSTALL NO. 2 CYLINDER HEAD COVER (w/ No. 2 Cylinder Head Cover)

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