EGR Cooler: Installation

Install the stud bolt to the cylinder head RH, and set the gasket (A) to the stud bolt.
NOTE: Use a new stud bolt and gasket.

Tightening torque:

6.4 N.m (0.7 kgf-m, 4.7 ft-lb)

Fig 1: Locating Stud Bolts To Cylinder Head RH
Courtesy of SUBARU OF AMERICA, INC.
Set the EGR cooler to the EGR control valve and cylinder head RH, and temporarily tighten the bolts which secure the EGR cooler to the EGR control valve and cylinder head RH.
NOTE: Use a new gasket.

Fig 2: Locating EGR Cooler Gasket Bolts
Courtesy of SUBARU OF AMERICA, INC.
Connect the engine coolant inlet hose to the EGR cooler.

Fig 3: Locating Engine Coolant Inlet Hose To EGR Cooler With Clip
Courtesy of SUBARU OF AMERICA, INC.
Lift up the vehicle.
Connect the water hose to the water pipe RH.

Fig 4: Locating Water Hose To Water Pipe RH
Courtesy of SUBARU OF AMERICA, INC.
Install the EGR cooler to the cylinder head RH.
1. Tighten the nuts which secure the EGR cooler to the cylinder head RH in numerical order as shown in the figure.
  Tightening torque:
  
  9 N.m (0.9 kgf-m, 6.6 ft-lb)
  
  Fig 5: EGR Cooler Nuts Tightening Sequence
  Courtesy of SUBARU OF AMERICA, INC.
2. Retighten the nut shown in the figure.
  Tightening torque:
  
  9 N.m (0.9 kgf-m, 6.6 ft-lb)
Fig 6: Locating EGR Cooler Nut
Courtesy of SUBARU OF AMERICA, INC.
Tighten the bolts holding the EGR cooler to the cylinder head RH.
Tightening torque:

T1: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
Tighten the bolt securing the EGR cooler to the EGR control valve.
Tightening torque:

T2: 19 N.m (1.9 kgf-m, 14.0 ft-lb)

Fig 7: Locating EGR Cooler To EGR Control Valve With Bolts
Courtesy of SUBARU OF AMERICA, INC.
Connect the engine coolant outlet hose to the CVTF cooler (with warmer feature).

Fig 8: Locating Engine Coolant Outlet Hose To CVTF Cooler (With Warmer Feature) With Clip
Courtesy of SUBARU OF AMERICA, INC.
Lower the vehicle.
Install the brake booster vacuum hose to the clip.
NOTE: If the clip is removed from the intake manifold, install the clip to the position of alignment mark of intake manifold.

Fig 9: Locating Brake Booster Vacuum Hose To Clips
Courtesy of SUBARU OF AMERICA, INC.
Install the intercooler. Ref. to INTAKE (INDUCTION) (H4DOTC)>Intercooler>INSTALLATION .
Connect the battery ground terminal.
Fill engine coolant. Ref. to COOLING(H4DOTC)>Engine Coolant>REPLACEMENT>FILLING OF ENGINE COOLANT .
Install the collector cover.