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.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

  2. INSTALL NO. 2 EGR VALVE ASSEMBLY

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

      Tip:

      Make sure that the claw of the gasket is facing the EGR pipe with cooler sub-assembly.

  3. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

    1. Install a new gasket to the No. 2 EGR valve assembly.

    2. Temporarily install the No. 1 EGR pipe sub-assembly with the 2 bolts and 2 nuts.

      Tip:

      Tighten the bolts and nuts until there is no gap between the No. 1 EGR pipe sub-assembly, No. 2 EGR valve assembly and EGR pipe with cooler sub-assembly.

  4. INSTALL EGR PIPE WITH COOLER SUB-ASSEMBLY

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

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

    3. Temporarily install the EGR pipe with cooler sub-assembly with the 6 bolts and 2 nuts.

      A293450C01
      V100135

      Bolt

      		 V100136

      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 (A) and 2 nuts (A) shown in the illustration.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

    5. Tighten the 2 bolts (B) shown in the illustration.

      16 N*m

      163 kgf*cm

      12 ft.*lbf

    6. Tighten the 2 bolts (C) shown in the illustration.

      24 N*m

      245 kgf*cm

      18 ft.*lbf

    7. Tighten the 2 bolts (D) and 2 nuts (D) shown in the illustration.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

    8. Connect the vacuum hose.

  5. INSTALL NO. 2 WATER BY-PASS HOSE

    1. Install the No. 2 water by-pass hose, and slide the 2 clips to secure it.

  6. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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