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 10 Nm (89 in. lbs.).





6. Install the outside bracket bolts (2). Tighten bolts (2) to 24 Nm (18 ft. lbs.).
7. Connect EGR bypass valve harness 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 10 Nm (89 in. lbs.).
10. Install upper heat shield (6) and nuts (7). Tighten nuts to 10 Nm (89 in. lbs.).





11. Clean each end of EGR crossover tube and its connection points of any old gasket material
12. Install new gaskets to each end of the EGR crossover tube (2).
13. Position EGR crossover tube (2) to engine.
14. Install bolt (5) finger tight at center bottom of the EGR crossover tube.
15. First, tighten EGR tube clamp (1) to 10 Nm (89 in. lbs.), then tighten clamp (3) to 10 Nm (89 in. lbs.).
16. Tighten EGR crossover tube bolt (5) to 10 Nm (89 in. lbs.).
17. Connect the EGR temperature sensor harness connector (4).





18. Install the EGR crossover tube cover (2). Tighten bolts (1) to 10 Nm (89 in. lbs.).
19. Connect and both negative battery cables.