EGR COOLER INSTALLATION

PROCEDURE


  1. INSTALL NO. 1 EGR COOLER


    1. Install a new gasket and the No. 1 EGR cooler to the No. 2 EGR valve assembly with electric EGR control valve assembly with the 4 bolts.

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

  2. INSTALL NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. Temporarily install the No. 1 EGR cooler and No. 2 EGR valve assembly with electric EGR control valve assembly to the intake manifold with the 4 bolts.

    2. B00269HN01

      Tighten the 4 bolts in the order shown in the illustration.

      Note

      Make sure to tighten the bolts in the order.

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

  3. INSTALL VACUUM CONTROL VALVE SET

    Click here

  4. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY (w/o DPF)

    Click here

  5. INSTALL EGR PIPE WITH COOLER SUB-ASSEMBLY (w/ DPF)

    Click here

  6. CONNECT NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

  7. INSTALL NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Install the No. 3 water by-pass pipe sub-assembly to the No. 1 EGR cooler with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Connect the No. 9 water by-pass hose to the electric EGR control valve assembly, and slide the clamp to secure the hose.

    3. Connect the No. 8 water by-pass hose to the No. 3 water by-pass pipe sub-assembly, and slide the clamp to secure the hose.

    4. Connect the No. 4 fuel hose to the No. 3 water by-pass pipe sub-assembly.

  8. INSTALL NO. 2 EGR PIPE

    Click here

  9. INSTALL EGR VALVE BRACKET

    Click here

  10. CONNECT ENGINE WIRE

    Click here

  11. INSTALL NO. 1 UREA TANK FILLER PIPE SUPPORT (w/ Urea SCR System)

    Click here

  12. CONNECT UREA TANK FILLER PIPE ASSEMBLY (w/ Urea SCR System)

    Click here

  13. CONNECT FUEL FILTER ASSEMBLY

    Click here

  14. INSTALL NO. 2 ENGINE COVER BRACKET

    Click here

  15. INSTALL NO. 2 HOSE TO HOSE TUBE

    Click here

  16. INSTALL TURBO PRESSURE SENSOR

    Click here

  17. INSTALL GAS FILTER

    Click here

  18. INSTALL NO. 2 WATER BY-PASS PIPE

    Click here

  19. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Click here

  20. ADD ENGINE COOLANT

    Click here

  21. INSPECT FOR COOLANT LEAK

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