EGR VALVE (w/o EGR Cooler) INSTALLATION


  1. TEMPORARILY INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ Intercooler)


    1. Place a new gasket, the electric EGR control valve, another new gasket and the intake air connector onto the stud bolts of the No. 2 intake air connector and temporarily install the 3 nuts labeled A in the illustration.

      Note

      Temporarily install the nuts so that 0 to 2 threads of each stud bolt are visible as shown in the illustration.

    2. Install a new gasket and the EGR valve adapter to the electric EGR control valve with the 2 bolts labeled B in the illustration.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

      Note

      Make sure the claws of the gasket face the electric EGR control valve as shown in the illustration.

    3. Set a new gasket on the intake manifold.

      Note

      Make sure the claws of the gasket face the intake manifold as shown in the illustration.

    4. Temporarily install the intake air connector to the intake manifold with the 3 bolts labeled C in the illustration.

      A01E1JWE02
      Text in Illustration
      *1 No. 2 Intake Air Connector *2 Electric EGR Control Valve
      *3 Intake Air Connector *4 EGR Valve Adapter
      *5 New Gasket *6 Claw
      *7 Intake Manifold - -
      *a 0 to 2 threads - -

  2. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/o Intercooler)


    1. Install a new gasket and the electric EGR control valve.

    2. Connect the EGR valve position sensor connector.

  3. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY


    1. w/ Intercooler:


      1. Temporarily install the No. 1 EGR pipe and 2 new gaskets to the cylinder head and EGR valve adapter with the 2 nuts and 2 bolts.

        Note

        Make sure the claws of the gasket face the No. 1 EGR pipe as shown in the illustration.

      2. Tighten the 2 nuts labeled A.

        Torque:
        13 N*m  { 133 kgf*cm, 10 ft.*lbf }

      3. Tighten the 2 bolts labeled B.

        Torque:
        13 N*m  { 133 kgf*cm, 10 ft.*lbf }
        A01DY4LE01
        Text in Illustration
        *1 New Gasket *2 Claw
    2. A01DY8CE01
      Text in Illustration
      *1 Claw

      w/o Intercooler:

      Install 2 new gaskets and the No. 1 EGR pipe with the 2 nuts and 2 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

      Tech Tips

      Make sure the claws of the gasket face the No. 1 EGR pipe.

  4. TIGHTEN INTAKE AIR CONNECTOR (w/ Intercooler)


    1. Tighten the 3 nuts labeled A in the illustration.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Tighten the 3 bolts labeled B in the illustration.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Note

      Tighten the bolts in the order shown in the illustration.

      A01DZ5LE02
      Text in Illustration
      *a Front Side of Vehicle - -

  5. INSTALL INTAKE AIR CONNECTOR (w/o Intercooler)


    1. Install a new gasket and the intake air connector with the 2 nuts and bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  6. INSTALL NO. 2 INTAKE AIR CONNECTOR BRACKET


    1. w/ Intercooler:


      1. A01E1G1E01

        Temporarily install the No. 2 intake air connector bracket with the 3 bolts.

      2. Tighten the bolt labeled A.

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      3. Tighten the 2 bolts labeled B.

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. w/o Intercooler:

      Install the No. 2 intake air connector bracket with the 3 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  7. INSTALL ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (for EGR)


    1. w/ Intercooler:


      1. Install the electric vacuum regulating valve bracket with the 2 bolts.

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      2. Install the No. 1 gas filter with gas filter bracket with the bolt.

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      3. Connect the 6 vacuum hoses.

        Note

        Be sure to securely connect the vacuum hoses.

      4. Connect the 2 connectors.

    2. w/o Intercooler:


      1. Install the electric vacuum regulating valve together with the bracket with the 2 bolts.

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      2. Connect the 2 vacuum hoses.

      3. Connect the connector.

  8. INSTALL NO. 3 WATER BY-PASS PIPE (w/ Intercooler)


    1. Connect the No. 3 water by-pass pipe with wire harness with the 2 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  9. INSTALL NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY (w/ Intercooler)

    Note


    • When replacing an injector, it is necessary to replace the 4 injection pipes with new ones.

    • Keep the joints of the injection pipes clean.


    1. Temporarily install the No. 1, No. 2 and No. 3 injection pipes with the union nuts.

    2. A01E2W0E01
      Text in Illustration
      *1 No. 2 Injection Pipe
      *2 No. 2 Injection Pipe Clamp
      *3 No. 3 Injection Pipe Clamp
      *4 Painted Mark

      w/ Intercooler:

      Install the No. 2 and No. 3 injection pipe clamps with the 2 bolts and 2 nuts as shown in the illustration.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Tech Tips

      If the painted mark on the No. 2 injection pipe has disappeared, use the illustration as a reference to install the clamps.

    3. A01E1BWE01
      Text in Illustration
      *1 No. 1 Injection Pipe
      *2 No. 2 Injection Pipe Clamp
      *3 No. 3 Injection Pipe Clamp
      *4 Painted Mark

      w/o Intercooler:

      Install the No. 2 and No. 3 injection pipe clamps with the bolt and 2 nuts as shown in the illustration.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Tech Tips

      If the painted mark on the No. 1 injection pipe has disappeared, use the illustration as a reference to install the clamps.

    4. Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the common rail side.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    5. Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the injector side.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  10. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Click here

  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  12. BLEED AIR FROM FUEL SYSTEM (w/ Intercooler)


    1. A01DYNDE02

      Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.

      Note


      • Hand pump pumping speed: Max. 2 strokes/ sec.

      • The hand pump must be pushed with a full stroke during pumping.

      • When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.

      • If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.

      • If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.

      • If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use, and the engine cannot be started.

    2. Check if the engine starts.

      Note


      • Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.

      • Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.

      • Use a fully-charged battery.


      1. When the engine can be started, proceed to the next step.

      2. If the engine cannot be started, bleed the air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.

    3. Turn the ignition switch off.

    4. Connect the intelligent tester to the DLC3.

    5. Turn the ignition switch to ON and turn the intelligent tester on.

    6. Clear the DTCs Click here.

    7. Start the engine.*1

    8. Enter the following menus: Powertrain / Engine / Active Test / Test the Fuel Leak.*2

    9. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

    10. Allow the engine to idle for 3 minutes or more after performing the Active Test for the fifth time.

      A01DYT1E05

      Tech Tips

      When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.

    11. Enter the following menus: Powertrain / Engine / DTC.

    12. Read Current DTCs.

    13. Clear the DTCs Click here.

      Tech Tips

      It is necessary to clear the DTCs, as DTC P1604 or P1605 may be stored when air is bled from the fuel system after replacing or repairing fuel system parts.

    14. Repeat steps *1 to *3.

    15. Enter the following menus: Powertrain / Engine / DTC.

    16. Read Current DTCs.

      OK
      No DTCs are output.

  13. INSPECT FOR FUEL LEAK (w/ Intercooler)

    CAUTION:


    • During Active Test mode, the engine speed becomes high and the combustion noise becomes loud, so pay attention.

    • During Active Test mode, the fuel pressure becomes high. Be extremely careful not to expose your eyes, hands, or body to escaping fuel.


    1. Check that there are no leaks from any part of the fuel system when the engine is stopped. If there is fuel leakage, repair or replace parts as necessary.

    2. Start the engine and check that there are no leaks from any part of the fuel system. If there is fuel leakage, repair or replace parts as necessary.

    3. Disconnect the return hose from the common rail.

    4. Start the engine and check for fuel leaks from the return pipe.

      If there is fuel leakage, replace the common rail.

    5. Connect the intelligent tester to the DLC3.

    6. Start the engine and turn the intelligent tester main switch on.

    7. Select the Fuel Leak test from the Active Test mode on the intelligent tester.

    8. If the intelligent tester is not available, fully depress the accelerator pedal quickly. Increase the engine speed to the maximum and maintain that speed for 2 seconds. Repeat this operation several times.

    9. Check that there are no leaks from any part of the fuel system.

      Note

      A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.

      If there is fuel leakage, repair or replace parts as necessary.

    10. Reconnect the return hose to the common rail.