Exhaust Gas Recirculation (EGR) Cooler Bypass Valve - Installation

INSTALLATION





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 bolts at this time.





5. Install the inside bracket bolts (1). Tighten bolts (1) to 24 Nm (18 ft. lbs.).





6. Install the outside bracket bolts (2). Tighten bolts (2) to 24 Nm (18 ft. lbs.).
7. Connect electrical connector (1).





8. Tighten bolts (5) and (14) to 24 Nm (18 ft. lbs.).
9. Install lower heat shield (9), bolts (10), and nut (8). Tighten nut/bolts to 24 Nm (18 ft. lbs.).
10. Install upper heat shield (6) and nuts (7). Tighten nuts to 24 Nm (18 ft. lbs.).





11. Clean gasket mating surfaces of EGR crossover tube.
12. Install new gaskets, (2) and (5), to each end of tube.
13. Position EGR crossover tube (4) to engine.
14. Install the bolt (3) (finger tight) to the EGR crossover tube.
15. Tighten EGR tube clamp (1) and (6) to 10 Nm (7 ft. lbs.).
16. Tighten EGR crossover tube bolt (3) to 10 Nm (7 ft. lbs.).





17. Install engine cover and tighten the four bolts (1).
18. Connect and both negative battery cables.