Installation-Pick Up Models

INSTALLATION-PICK UP MODELS





1. Clean gasket mating surfaces on castings (4) and (15).
2. Position EGR cooler bypass valve assembly to engine.
3. Position new gasket (3) between castings (4) and (15).
4. Install bolts (5) and (14). Do not tighten these bolts at this time.




5. Install bracket bolts (2) at outside of mounting bracket. Do not tighten these bolts at this time.
6. Install bracket bolts at inside of mounting bracket. Do not tighten these bolts at this time.




7. Tighten bolts (5) and (14) to 24 Nm (18 ft. lbs.) torque.




8. Tighten bracket bolts (2) at outside of mounting bracket to 24 Nm (18 ft. lbs.) torque.
9. Tighten bracket bolts at inside of mounting bracket to 24 Nm (18 ft. lbs.) torque.
10. Connect electrical connector (1).




11. Clean each end of EGR crossover tube and its connection points of any old gasket material
12. Install new gaskets (doughnuts) (2) and (5) to each end of tube.
13. Position EGR crossover tube (4) to engine.
14. Position bolt (3) at center of EGR crossover tube. Install bolt loosely (finger tight).
15. First, tighten EGR tube clamp (1) to 10 Nm (7 ft. lbs.), then tighten clamp (6) to 10 Nm (7 ft. lbs.).
16. Tighten clamp bolt (3) to 10 Nm (7 ft. lbs.).




17. Install upper heat shield (6) and nuts (7). Tighten nuts to 24 Nm (18 ft. lbs.) torque.
18. Install lower heat shield (9), bolts (10), and nut (8). Tighten nut/bolts to 24 Nm (18 ft. lbs.) torque.




19. Install EGR tube cover (1) and four bolts (2).
20. Connect and both negative battery cables to both batteries.