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. SET EGR VALVE ASSEMBLY

HINT:

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

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(a) Set the EGR valve assembly to the camshaft housing.

HINT:

At this time, do not install the parts with bolts.

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

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

2. INSTALL EGR COOLER ASSEMBLY

(a) Install a new EGR cooler gasket to the EGR cooler assembly. NOTICE: Make sure that the claws of the EGR cooler gasket are toward the EGR cooler assembly side.

*a Claw

(b) Install a new EGR valve gasket to the EGR cooler assembly.

NOTICE:

Make sure that the claws of the EGR valve gasket are toward the EGR cooler assembly side.

(c) Type A: (1) Temporarily install the EGR cooler assembly to the cylinder head sub-assembly and EGR valve assembly with the 3 bolts and 2 nuts. (2) Tighten the 3 bolts and 2 nuts in the order shown in the illustration. Torque: 24 N·m {245 kgf·cm, 18 ft·lbf}

*a Bolt or Nut

(d) Type B:

(1) Temporarily install the EGR cooler assembly to the cylinder head sub-assembly and EGR valve assembly with the 2 bolts and 3 nuts.

(2) Tighten the 2 bolts and 3 nuts in the order shown in the illustration.

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

(e) Connect the No. 3 water by-pass hose and No. 4 water by-pass hose to the EGR cooler assembly and slide the 2 clips to secure them.

3. INSTALL EGR VALVE ASSEMBLY

(a) Using an 8 mm socket wrench, install the EGR valve assembly to the camshaft housing with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

4. 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}

5. CONNECT ENGINE WIRE

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

(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.

6. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

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7. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

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8. ADD ENGINE COOLANT

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9. INSPECT FOR COOLANT LEAK

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10. INSPECT FOR EXHAUST GAS LEAK

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