EGR COOLER INSTALLATION

PROCEDURE


  1. INSTALL EGR VALVE ASSEMBLY

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  2. INSTALL EGR COOLER ASSEMBLY


    1. Install the EGR cooler assembly to the cylinder head sub-assembly with the 2 nuts and bolt.

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

    2. Connect the No. 4 water by-pass hose to the EGR valve assembly and slide the clip to secure it.

    3. Connect the No. 12 water by-pass hose to the EGR valve assembly and slide the clip to secure it.

    4. Connect the No. 5 water by-pass hose to the EGR cooler assembly and slide the clip to secure it.

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

  3. INSTALL EGR VALVE BRACKET


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      Temporarily install the EGR valve bracket to the EGR valve assembly and cylinder head sub-assembly with the 2 bolts.

      Tech Tips

      Temporarily tighten the bolts until they are seated on the EGR valve bracket.

    2. Tighten the 2 bolts in the order shown in the illustration.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

  4. INSTALL NO. 2 EGR PIPE


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      *1 No. 2 EGR Pipe Gasket
      *2 Claws
      B008GAS Nut
      B008GGT Bolt

      Install a new No. 2 EGR pipe gasket to the EGR valve assembly as shown in the illustration.

      Note

      Make sure that the gasket is installed in the correct direction.

    2. Install a new EGR inlet gasket to the intake manifold.

    3. Temporarily install the No. 2 EGR pipe to the EGR valve assembly and intake manifold with the 2 bolts and 2 nuts.

      Tech Tips

      Temporarily tighten the bolts and nuts until they are seated on the No. 2 EGR pipe.

    4. Tighten the 2 nuts while pressing the No. 2 EGR pipe against the EGR valve assembly side.

      Torque:
      10 N*m  { 102 kgf*cm, 89 in.*lbf }

    5. Tighten the 2 bolts.

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

  5. INSTALL ENGINE MOTOR CABLE CLAMP BRACKET


    1. A01O9HCN01

      Install the engine motor cable clamp bracket to the EGR cooler assembly and cylinder head sub-assembly with the 2 bolts in the order shown in the illustration.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

  6. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND

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