EGR COOLER INSTALLATION

PROCEDURE

  1. INSTALL EGR VALVE ASSEMBLY

    Click here

  2. INSTALL EGR COOLER ASSEMBLY WITH EGR VALVE ASSEMBLY

    1. Install a new water pipe to the EGR cooler assembly.

    2. Install a new gasket to the No. 2 EGR pipe sub-assembly.

      Tip:

      Make sure that the claw of the gasket faces the No. 2 EGR pipe sub-assembly.

    3. Temporarily install the EGR cooler assembly with EGR valve assembly with the 7 bolts.

    4. A346733

      Using a T45 "TORX" socket wrench, tighten the 2 bolts.

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

    5. Loosen the 2 bolts 90°.

    6. U122299E02

      Tighten the 7 bolts labeled A, B and C, and then 2 nuts in the order shown in the illustration.

      for bolt A

      13 N*m

      133 kgf*cm

      10 ft.*lbf

      for bolt B

      19 N*m

      194 kgf*cm

      14 ft.*lbf

      for bolt C

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

      Table 1. Text in Illustration
      V100135

      Bolt A
      V100136

      Bolt B
      V100137

      Bolt C
      Tip:

      • When tightening the bolts labeled A, use a T45 "TORX" socket wrench.

      • When tightening the bolts labeled B, use a 6 mm hexagon wrench.

    7. Connect the vacuum hoses to the EGR cooler assembly.

    8. Connect the hose clamp to the EGR cooler hose.

    9. Attach the clamp and connect the engine wire to the EGR valve assembly.

    10. Connect the EGR valve assembly connector.

  3. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    1. Install the No. 1 exhaust manifold heat insulator with the 2 bolts.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

    2. Attach the 2 clamps and connect the engine wire.

    3. Attach the 2 clamps and connect the air fuel ratio sensor.

    4. A340627E03

      Lower the air fuel ratio sensor connector to the position shown in the illustration and connect the air fuel ratio sensor connector.

      Table 2. Text in Illustration

      *1

      Air Fuel Ratio Sensor

      *2

      Bracket

      *a

      1.5 mm (0.0591 in.) or less

  4. INSTALL NO. 1 TURBO INSULATOR

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  5. CONNECT FUEL FEED PIPE SUB-ASSEMBLY

    1. Connect the fuel feed pipe sub-assembly to the fuel pipe clamp.

    2. Connect the vacuum hose to the No. 2 fuel hose.

    3. Connect the fuel feed pipe sub-assembly with the 2 bolts.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

    4. Attach the 2 clamps and connect the engine wire.

  6. CONNECT NO. 1 AIR TUBE ASSEMBLY

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  7. INSTALL NO. 4 WATER BY-PASS HOSE

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  8. CONNECT ENGINE WIRE

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  9. CONNECT COMPRESSOR OUTLET ELBOW

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  10. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

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  11. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  12. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY

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  13. INSTALL BATTERY CARRIER

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  14. INSTALL BATTERY TRAY

  15. INSTALL BATTERY

  16. INSTALL BATTERY INSULATOR

  17. INSTALL BATTERY CLAMP SUB-ASSEMBLY

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  18. INSTALL RADIATOR SUPPORT OPENING COVER

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  19. CONNECT CABLE TO POSITIVE BATTERY TERMINAL

  20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

  21. ADD ENGINE COOLANT

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  22. INSPECT FOR COOLANT LEAK

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  23. INSTALL NO. 1 ENGINE UNDER COVER

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  24. PERFORM INITIALIZATION

    1. Perform EGR learning value reset (Click here).