INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE

1. INSTALL EGR VALVE ASSEMBLY

(a) Using an 8 mm socket wrench, install the EGR valve assembly to the EGR valve bracket with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Align and fit the hole of the EGR valve bracket to the pin of the camshaft housing.

*a Pin *b Hole

(c) Using the 8 mm socket wrench, install the EGR valve assembly with the EGR valve bracket to the camshaft housing with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(d) for EGR Valve Bracket Connection Type:

(1) Using the 8 mm socket wrench, connect the fuel pipe sub-assembly to the EGR valve bracket with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(e) Install the EGR cooler bracket to the EGR valve bracket and water outlet with the 2 bolts.

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

(f) w/ Water Hose Connector:

*a	Retainer
	Push in

(1) Align the water hose connector with the EGR valve assembly, push the No. 4 water by-pass hose onto the EGR valve assembly, then push in the retainer to secure the connection.

NOTICE:

Confirm that the retainer makes a "click" sound when pushed.

(2) Check that the EGR valve assembly and No. 4 water by-pass hose are securely connected by pulling on them.

(g) w/o Water Hose Connector:

(1) Install the No. 4 water by-pass hose to the EGR valve assembly and slide the clip to secure it.

(h) Connect the No. 8 water by-pass hose to the EGR valve assembly and slide the clip to secure it.

2. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

(a) Install a new EGR inlet gasket to the intake manifold.

(b) Install a new EGR valve adapter gasket to the No. 1 EGR pipe sub-assembly.

(c) Using an 8 mm socket wrench, install the No. 1 EGR pipe sub-assembly to the intake manifold and EGR valve assembly with the 4 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

3. CONNECT ENGINE WIRE

(a) Engage the 2 wire harness clamps to connect the engine wire.

*a No. 5 Engine Wire Connector *b EGR Valve Assembly Connector

(b) Install the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(c) Connect the EGR valve assembly connector.

(d) Connect the No. 5 engine wire connector.

4. INSTALL EGR COOLER ASSEMBLY

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5. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

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6. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

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7. ADD ENGINE COOLANT

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8. INSPECT FOR COOLANT LEAK

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9. INSPECT FOR EXHAUST GAS LEAK

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