RM38T0EC _51 Engine / Hybrid System _144996 M20F-FXS, M20G-FXS EMISSION CONTROL _0604306 EGR COOLER A

M20F-FXS, M20G-FXS EMISSION CONTROL  EGR COOLER  INSTALLATION  


CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)
A522686N01
0.083,3.333 0.667,3.5 0.583,0.167 2.417,3.5 3,3.667 0.583,0.167 1.833,2.375 2.5,2.542 0.667,0.167 4.885,2.552 5.552,2.719 0.667,0.167 6.479,0.25 6.813,0.25 false 6.469,0.667 6.802,0.667 false 5.125,2.083 5.458,2.083 false 3.417,0.604 3.583,0.604 3.583,0.604 3.75,0.833 false 1.615,1.24 1.948,1.24 false 2.156,1.625 2.49,1.625 false 4.531,3.667 4.865,3.667 false 1.667,3 1.833,3 1.833,3 1.833,4.333 true 2.417,3.583 2.104,3.583 2.104,3.583 2.104,4.396 true 2.25,3.583 2.25,4.333 true 0.667,3.417 1.75,3.417 1.75,3.417 1.75,4.75 true 1.667,3.417 1.667,4.531 true 1.25,3.417 1.25,4.385 true 1.104,3.417 1.104,4.292 true 1.75,5.417 1.583,5.417 1.583,5.417 1.24,4.625 true 4.552,2.625 4.885,2.625 false 2.5,2.458 2.833,2.458 false 4.479,0.5 4.813,0.5 false 2.917,1.969 3.229,2.167 0.313,0.198 10 false x2 4.438,2.688 4.75,2.885 0.313,0.198 10 false *b 2.854,2.479 3.167,2.677 0.313,0.198 10 false *a 2.073,5.333 2.75,5.635 0.677,0.302 18 true 1, 9 1.135,2.833 1.646,3.115 0.51,0.281 18 false 2, 8 3.177,0.49 3.458,0.844 0.281,0.354 18 false 3 1.427,1.073 1.708,1.427 0.281,0.354 18 false 4 1.927,1.5 2.208,1.854 0.281,0.354 18 false 5 4.188,3.5 4.542,3.844 0.354,0.344 18 false 10 5.521,1.917 5.802,2.271 0.281,0.354 18 false 7 6.125,0.5 6.458,0.76 0.333,0.26 18 false 11 5.719,0.083 6.49,0.354 0.771,0.271 18 false 12, 13 3.052,0.542 3.365,0.74 0.313,0.198 10 false ● 0.094,3.333 0.844,3.49 0.75,0.156 8 false 10 (102, 7) 2.438,3.5 3.188,3.656 0.75,0.156 8 false 10 (102, 7) 1.865,2.375 2.615,2.531 0.75,0.156 8 false 24 (245, 18) 4.917,2.552 5.667,2.708 0.75,0.156 8 false 24 (245, 18) 1.26,1.146 1.573,1.344 0.313,0.198 10 false ● 4.885,0.313 5.167,0.667 0.281,0.354 18 false 6

Procedure Part Name Code
Z101186

Z101188

Z101187

1 LOOSEN NO. 1 EGR PIPE SUB-ASSEMBLY 25601 (Click here) - -
2 LOOSEN EGR VALVE ASSEMBLY 25620 (Click here) - -
3 NO. 1 EGR COOLER GASKET 25685 (Click here) - -
4 EGR VALVE GASKET 25627 (Click here) - -
5 EGR COOLER ASSEMBLY 25680 (Click here) - -
6 NO. 4 WATER BY-PASS HOSE 16281 - - -
7 NO. 3 WATER BY-PASS HOSE 16267 - - -
8 TIGHTEN EGR VALVE ASSEMBLY 25620 (Click here) - -
9 TIGHTEN NO. 1 EGR PIPE SUB-ASSEMBLY 25601 (Click here) - -
10 INVERTER WITH CONVERTER ASSEMBLY G92A0 - - -
11 ADD ENGINE COOLANT - - (Click here) -
12 INSPECT FOR COOLANT LEAK - (Click here) - -
13 INSPECT FOR EXHAUST GAS LEAK - (Click here) - -

*a x2 or x3 *b x3 or x2
V100146

N*m (kgf*cm, ft.*lbf): Specified torque ● Non-reusable part

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 hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION


PROCEDURE

Hide 25601 1.LOOSEN NO. 1 EGR PIPE SUB-ASSEMBLY

a.
A466680N03
0.531,0.146 0.813,0.5 0.281,0.354 18 false i

i.

Using an 8 mm socket wrench, loosen the 4 bolts of the No. 1 EGR pipe sub-assembly.

NOTICE:
·

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.





Hide 25620 2.LOOSEN EGR VALVE ASSEMBLY

a.
A466681N07
0.521,0.125 1.344,0.625 0.823,0.5 18 false i

i.

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



Hide 25685 3.INSTALL NO. 1 EGR COOLER GASKET

a.
A466679C02
2.865,1 2.313,0.802 2.313,0.802 2.75,1.177 true 2.75,1.438 2.25,1.688 2.25,1.688 2.896,1.552 true 2.094,0.708 2.542,1.083 0.448,0.375 10 false *a 2.052,1.594 2.51,1.781 0.458,0.188 10 false *a 0.563,0.167 0.958,0.594 0.396,0.427 18 false i
*a Claw - -


i.

Install a new No. 1 EGR cooler gasket to the EGR cooler assembly.

NOTICE:

Make sure that the claws of the No. 1 EGR cooler gasket are toward the EGR cooler assembly side.




Hide 25627 4.INSTALL EGR VALVE GASKET

a.
A466677C02
4.573,0.458 4.76,0.24 4.76,0.24 4.26,0.396 true 4.25,0.74 4.698,1.219 4.698,1.219 4.49,0.719 true 4.844,0.146 5.292,0.521 0.448,0.375 10 false *a 4.688,1.281 5.208,1.573 0.521,0.292 10 false *a 0.5,0.104 0.927,0.552 0.427,0.448 18 false i
*a Claw - -


i.

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.




Hide 25680 5.INSTALL EGR COOLER ASSEMBLY

a.
A522865N01
3.323,1.542 3.51,1.719 0.188,0.177 10 true 1 4.479,1.542 4.667,1.719 0.188,0.177 10 true 3 4.594,0.854 4.781,1.031 0.188,0.177 10 true 2 3.594,0.25 3.781,0.427 0.188,0.177 10 true 4 2.354,0.156 2.542,0.333 0.188,0.177 10 true 5 0.438,0.031 0.76,0.438 0.323,0.406 18 false i, ii

[The illustrations are representative examples, and details may differ.]


i.

Temporarily install the EGR cooler assembly to the cylinder head sub-assembly and EGR valve assembly with the bolts and nuts.


ii.

Tighten the bolts and nuts in the order shown in the illustration.

Torque:
24 N*m (245 kgf*cm, 18 ft.*lbf)



Hide 16281 6.CONNECT NO. 4 WATER BY-PASS HOSE

Hide 16267 7.CONNECT NO. 3 WATER BY-PASS HOSE

Hide 25620 8.TIGHTEN EGR VALVE ASSEMBLY

a.
A466681N08
0.531,0.125 1.313,0.667 0.781,0.542 18 false i

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)



Hide 25601 9.TIGHTEN NO. 1 EGR PIPE SUB-ASSEMBLY

a.
A466680N04
0.5,0.135 0.927,0.646 0.427,0.51 18 false i

i.

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)