8ZR-FXE EMISSION CONTROL  EGR COOLER  INSTALLATION  

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)

1.417,2.979 1.625,3.188 0.208,0.208 10 false *a 2.417,1.865 2.771,2.083 0.354,0.219 10 false *b 2.156,2.021 2.448,2.25 0.292,0.229 10 false *d 1.833,2.417 2.125,2.646 0.292,0.229 10 false *c

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

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.

0.344,2.135 1.625,3.292 1.281,1.156 1.802,2.135 3.083,3.292 1.281,1.156 0.417,2.177 0.698,2.406 0.281,0.229 10 false *a 1.219,1.771 1.427,1.958 0.208,0.188 10 true *b 0.458,2.771 0.667,3.031 0.208,0.26 10 false *c 1.375,2.583 1.688,2.854 0.313,0.271 10 false *d 1.375,3.01 1.677,3.229 0.302,0.219 10 false *e 1.948,2.781 2.271,3.052 0.323,0.271 10 false *f 2.833,2.604 3.146,2.854 0.313,0.25 10 false *g 2.844,3.01 3.156,3.229 0.313,0.219 10 false *h 0.865,0.656 1.063,0.833 0.198,0.177 10 true *a 1.865,2.188 2.073,2.375 0.208,0.188 10 false *b

*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.)

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)

0,0 0,0 false

	Bolt
	Nut

Tighten the bolt and 2 nuts.

Torque:

21 N*m (214 kgf*cm, 15 ft.*lbf)

Tighten the 2 nuts.

Torque:

26 N*m (265 kgf*cm, 19 ft.*lbf)

2.396,0.552 2.74,0.719 true 2.406,0.25 2.719,0.406 0.313,0.156 10 false *a 1.49,0.75 1.802,0.906 0.313,0.156 10 false *b 2.781,0.646 3.094,0.802 0.313,0.156 10 false *c 1.906,0.167 2.219,0.323 0.313,0.156 10 false *d 0.823,1.292 1.135,1.448 0.313,0.156 10 false *e

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

Type A:

2.396,0.75 2.708,0.938 true 2.385,0.438 2.698,0.635 0.313,0.198 10 false *a 2.729,0.844 3.042,1.042 0.313,0.198 10 false *c 1.521,0.958 1.833,1.156 0.313,0.198 10 false *b 0.896,1.542 1.208,1.74 0.313,0.198 10 false *e

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

Type B:

2.385,0.708 2.51,0.302 2.51,0.302 2.656,0.302 true 2.292,0.24 2.521,0.49 0.229,0.25 10 false *a 1.74,0.823 2,1.063 0.26,0.24 10 false *b 2.708,0.219 3.083,0.51 0.375,0.292 10 false *c 2.083,0.385 2.344,0.625 0.26,0.24 10 false *d

*a	Up
*b	LH
*c	Paint Mark
*d	120°

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.

2.354,0.969 2.688,1.146 2.688,1.146 2.833,1.146 true 2.063,0.156 2.375,0.344 0.313,0.188 10 false *a 2.813,0.875 3.104,1.115 0.292,0.24 10 false *b 2.865,1.063 3.156,1.333 0.292,0.271 10 false *c 2.521,0.469 2.823,0.708 0.302,0.24 10 false *d

*a	Up
*b	LH
*c	Paint Mark
*d	180°

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.