EGR VALVE INSTALLATION


  1. TEMPORARILY TIGHTEN ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. Temporarily tighten the EGR valve assembly with the sensor.


      1. B007UFUE01

        Install 2 new gaskets and the EGR valve to the intake air connector as shown in the illustration.

      2. B007QH9

        Temporarily tighten the intake air connector with EGR valve assembly to the intake manifold with the bolt and the 2 nuts.

      3. Install the vacuum hose to the intake air connector.

      4. Temporarily tighten the manifold stay with the bolt.

      5. B007Q7Z

        Connect the EGR valve position sensor connector.

      6. Connect the intake air temperature sensor connector.

    2. Install the vacuum regulating valve.


      1. B007SOX

        Install the vacuum regulating valve with the 2 bolts.

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

      2. Connect the 2 vacuum hoses and the regulating valve connector.

  2. INSTALL EGR PIPE SUB-ASSEMBLY NO.1


    1. B007W39

      Install the 2 gaskets to the cylinder head and EGR pipe sub-assembly as shown in the illustration.

    2. B007S6J

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

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

    3. Tighten the intake air connector with the bolt and the 2 nuts.

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

    4. Tighten the manifold stay.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  3. REMOVE EGR PIPE SUB-ASSEMBLY NO.1


    1. Remove the 3 bolts, the 2 nuts, and the EGR pipe sub-assembly.

    2. Remove the 2 gaskets.

  4. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Note

    After removing and installing, or replacing the throttle body, be sure to perform the operation check.


    1. Install a new gasket to intake air connector.

    2. B007PX5

      Install the throttle body with the 2 bolts and the 2 nuts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    3. B007RAM

      Connect the 2 throttle body connectors.

  5. INSTALL AIR HOSE NO.4


    1. B007S1N

      Install the air hose No.4 with the 2 clamps.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  6. INSTALL EGR PIPE SUB-ASSEMBLY NO.1


    1. B007W39

      Install 2 new gaskets to the cylinder head and the EGR pipe sub-assembly No.1 as shown in the illustration.

    2. B007S6J

      Install the EGR pipe with the 2 bolts and the 2 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    3. B007QY1

      Connect the fuel pressure sensor connector.

  7. CONNECT OIL RETURN HOSE (w/ Intercooler)


    1. B007T4F

      Connect the oil return hose with the clip.

  8. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY


    1. B007PR9E01

      Install the vane pump oil reservoir assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  9. INSTALL ENGINE SERVICE HOLE COVER NO.2


    1. Install the engine service hole cover No.2 with the 3 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    2. B007P6F

      Return the carpet.

  10. CHECK FUNCTION OF THROTTLE BODY

    Click here

  11. INSTALL ENGINE UNDER COVER NO.1 (w/ Engine Under Cover No.1)

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