EGR VALVE INSTALLATION

PROCEDURE

  1. INSTALL EGR VALVE ASSEMBLY

    Tip:

    Perform "Inspection After Repair" after replacing the EGR valve assembly.

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    1. A423439

      Using an E8 "TORX" socket wrench, install the 2 stud bolts to the EGR valve assembly.

      Tip:

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

      7.5 N*m

      76 kgf*cm

      66 in.*lbf

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

    3. A423434

      Install the EGR valve assembly to the EGR cooler assembly with the 2 nuts.

      28 N*m

      286 kgf*cm

      21 ft.*lbf

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

  2. INSTALL EGR VALVE WITH COOLER ASSEMBLY

    1. A423438C01

      *a

      Convex Portion

      Install a new EGR valve gasket to the EGR cooler assembly as shown in the illustration.

    2. Temporarily install the EGR valve assembly with the EGR cooler assembly with the 2 bolts and 2 nuts.

    3. Install 2 new EGR pipe gaskets to the No. 1 EGR pipe sub-assembly and intake manifold.

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

    5. A423433C01

      *a

      Nut (A)

      *b

      Nut (B)

      *c

      Bolt

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

      Bolt and Nut (A)

      28 N*m

      286 kgf*cm

      21 ft.*lbf

      Nut (B)

      22.4 N*m

      228 kgf*cm

      17 ft.*lbf

    6. A423429N01

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

      10 N*m

      102 kgf*cm

      7 ft.*lbf

    7. Engage the wire harness clamp and connect the engine wire.

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

    9. Connect the water hose sub-assembly to the EGR cooler assembly and slide the clip to secure it.

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

    11. Connect the EGR valve assembly connector.

  3. INSTALL PURGE VALVE (PURGE VSV)

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  4. INSTALL AIR CLEANER ASSEMBLY WITH ELEMENT

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  5. ADD ENGINE COOLANT

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  6. INSPECT FOR COOLANT LEAK

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  7. PERFORM INITIALIZATION

    1. Perform "Inspection After Repair" after replacing the EGR valve assembly.

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