EGR COOLER INSTALLATION

PROCEDURE

  1. INSTALL STUD BOLT

    Tip:

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

    1. Using an E8 "TORX" socket wrench, install the 2 stud bolts to the EGR pipe with cooler sub-assembly.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  2. INSTALL EGR PIPE CONNECTOR

    1. Install a new gasket and No. 2 EGR valve assembly to the EGR pipe with cooler sub-assembly.

    2. Install a new gasket and EGR pipe connector with the bolt and 2 nuts.

      23 N*m

      235 kgf*cm

      17 ft.*lbf

  3. INSTALL EGR PIPE WITH COOLER SUB-ASSEMBLY

    1. Install 2 new gaskets to the cylinder head and EGR valve (electric EGR control valve assembly).

    2. Install the EGR pipe with cooler sub-assembly with the 4 bolts and 2 nuts.

      23 N*m

      235 kgf*cm

      17 ft.*lbf

    3. A295050C01

      *a

      View A

      *b

      Front Side

      Connect the No. 2 oil cooler hose and No. 2 water by-pass hose to the EGR pipe with cooler sub-assembly, and slide the 2 clips to secure them.

      Note:

      Engage the clip within the area shown in the illustration.

    4. Connect the vacuum hose to the No. 2 EGR valve assembly.

    5. Install the manifold absolute pressure sensor (diesel turbo pressure sensor) with the bolt and connect the vacuum transmitting hose.

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

    6. A235724

      Connect the 2 connectors and install the bolt.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

    7. Connect the connector and engage the wire harness clamp.

  4. INSTALL EGR BYPASS VALVE SWITCHING VALVE (NO. 1 VACUUM SWITCHING VALVE ASSEMBLY)

    Click here

  5. ADD ENGINE COOLANT

    Click here

  6. INSPECT FOR COOLANT LEAK

    Click here

  7. INSPECT FOR EXHAUST GAS LEAK

  8. INSTALL NO. 1 ENGINE COVER (w/ No. 1 Engine Cover)

    Click here