RM38N0EC _51 Engine / Hybrid System _111790 M20C-FKS, M20D-FKS EMISSION CONTROL _0503706 EGR COOLER A

M20C-FKS, M20D-FKS EMISSION CONTROL  EGR COOLER  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

Hide 25680 1.INSTALL EGR COOLER ASSEMBLY

a.
A453152

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.
A478647

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


c.
A433446C01
0.948,1.844 0.531,1.958 0.531,1.958 0.823,1.698 false 0.823,1.417 0.552,1.083 0.552,1.083 0.979,1.229 false 2.646,0.813 2.49,1.208 2.49,1.208 2.333,0.802 false 2.698,0.552 2.646,0.229 2.646,0.229 2.406,0.521 false 0.375,0.958 0.625,1.156 0.25,0.198 10 false *a 0.365,1.875 0.615,2.073 0.25,0.198 10 false *a 2.406,1.208 2.656,1.406 0.25,0.198 10 false *a 2.563,0.052 2.813,0.25 0.25,0.198 10 false *a
*a Claw


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.



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.
A478655C02
1.823,1.979 2.01,2.177 0.188,0.198 10 true 1 0.177,0.188 0.458,0.417 0.281,0.229 10 true 5 1.719,0.24 2,0.469 0.281,0.229 10 true 4 2.979,1.333 3.26,1.563 0.281,0.229 10 true 2 2.698,1.896 3.083,2.125 0.385,0.229 10 true 3 *a
*a Bolt or Nut


Type A:

i.

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


ii.

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

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



f.

Type B:

i.

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


ii.

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

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



g.

Using an 8 mm socket wrench, 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)


Hide 82121 2.CONNECT ENGINE WIRE

a.
A478651

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.
A478652

Engage the wire harness clamp.


e.
A478650

Engage the 3 wire harness clamps.


f.

Connect the 6 connectors.


g.
A478649

Engage the wire harness clamp.


h.

Connect the 4 connectors.


i.

Install the 3 bolts.

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)