INSTALLATION

PROCEDURE

1. INSTALL EGR PIPE WITH COOLER SUB-ASSEMBLY

(a) Using an E8 "TORX" socket wrench, install the 3 stud bolts to the EGR pipe with cooler sub-assembly. HINT: If a stud bolt is deformed or the threads are damaged, replace it. Torque: 5.0 N·m {51 kgf·cm, 44 in·lbf}

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

(c) Install the EGR pipe with cooler sub-assembly to the EGR valve assembly with the 2 nuts.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(d) Connect the No. 6 water by-pass hose to the EGR pipe with cooler sub-assembly and slide the clip to secure it. HINT: Engage the clip within the area shown in the illustration.

*a 0 to 4 mm (0 to 0.157 in.) *b LH *c Front of the vehicle *d 180°

(e) Install a new EGR cooler gasket to the EGR pipe with cooler sub-assembly.

(f) Set the EGR pipe with cooler sub-assembly with the EGR valve assembly to the engine assembly.

(g) Using an E8 "TORX" socket wrench, install the stud bolt (A) and stud bolt (B) to the cylinder head sub-assembly and camshaft housing sub-assembly. HINT: If a stud bolt is deformed or the threads are damaged, replace it. Torque: 9.5 N·m {97 kgf·cm, 84 in·lbf}

*a Stud Bolt (A) *b Stud Bolt (B) *c 48 mm (1.890 in.) *d 26 mm (1.024 in.) *e 13 mm (0.512 in.) *f 29 mm (1.142 in.) *g 14 mm (0.551 in.) *h 13 mm (0.512 in.)

(h) Temporarily install the EGR pipe with cooler sub-assembly with the EGR valve assembly to the cylinder head sub-assembly and camshaft housing sub-assembly with the bolt and 2 nuts.

(i) Temporarily install the EGR pipe with cooler sub-assembly to the exhaust manifold (TWC: Front Catalyst) with 2 new nuts.

(j) Tighten the bolt and 2 nuts.

	Bolt
	Nut

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(k) Tighten the 2 nuts. Torque: 26 N·m {265 kgf·cm, 19 ft·lbf}

(l) Connect the EGR valve assembly connector.

2. CONNECT NO. 4 WATER BY-PASS HOSE

(a) Connect the No. 4 water by-pass hose to the EGR pipe with cooler sub-assembly and slide the clip to secure it. HINT: Engage the clip within the area shown in the illustration.

*a Up *b LH *c Paint Mark *d 180° *e 0 to 4 mm (0 to 0.157 in.)

3. CONNECT INLET HEATER WATER HOSE

(a) Connect the inlet heater water hose to the EGR pipe with cooler sub-assembly and slide the clip to secure it. HINT: Engage the clip within the area shown in the illustration.

*a Up *b LH *c Paint Mark *d 120°

4. CONNECT WATER BY-PASS HOSE

(a) Connect the water by-pass hose to the EGR valve assembly and slide the clip to secure it. HINT: Engage the clip within the area shown in the illustration.

*a Up *b LH *c Paint Mark *d 180°

5. INSTALL EGR PIPE ASSEMBLY

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6. INSTALL INVERTER WITH CONVERTER ASSEMBLY

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7. ADD ENGINE COOLANT (for Engine)

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8. INSPECT FOR COOLANT LEAK (for Engine)

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9. INSPECT FOR EXHAUST GAS LEAK

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