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.

Click here

PROCEDURE

1. INSTALL EGR COOLER ASSEMBLY

(a) Using an 8 mm socket wrench, loosen the 4 bolts of the No. 1 EGR pipe sub-assembly. HINT: As the bolts of the No. 1 EGR pipe sub-assembly are only to be loosened, it is not necessary to replace the EGR inlet gasket and EGR valve adapter gasket. If the No. 1 EGR pipe sub-assembly is removed, it is necessary to replace the EGR inlet gasket and EGR valve adapter gasket with new ones.

(b) Using an 8 mm socket wrench, loosen the 2 bolts EGR valve assembly.

(c) 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

(d) 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.

(e) Type A: (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: 21 N·m {214 kgf·cm, 15 ft·lbf}

*a Bolt or Nut

(f) Type B:

(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:

21 N·m {214 kgf·cm, 15 ft·lbf}

(g) Install the wire harness clamp bracket to the EGR cooler assembly with the 2 bolts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

(h) 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.

(i) Using an 8 mm socket wrench, tighten the 2 bolts of the EGR valve assembly.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(j) Using an 8 mm socket wrench, tighten the 4 bolts of the No. 1 EGR pipe sub-assembly.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

2. CONNECT ENGINE WIRE

(a) Engage the wire harness clamp and connect the engine wire.

(b) Connect the 4 connectors.

(c) Install the bolt and 2 nuts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Engage the 3 wire harness clamps and connect the engine wire.

(e) Connect the 5 connectors.

(f) Engage the wire harness clamp and connect the engine wire.

(g) Connect the 4 connectors.

(h) Install the 3 bolts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

3. INSTALL BATTERY

Click here

4. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

Click here

5. ADD ENGINE COOLANT (for Fully Sealed Type)

Click here

6. ADD ENGINE COOLANT (for Non-Fully Sealed Type)

Click here

7. INSPECT FOR COOLANT LEAK (for Fully Sealed Type)

Click here

8. INSPECT FOR COOLANT LEAK (for Non-Fully Sealed Type)

Click here

9. INSPECT FOR EXHAUST GAS LEAK

Click here