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Hyundai Tucson: EGR cooler

Hyundai Tucson - Fourth generation (NX4) - (2020-2023) - Workshop Manual / Engine Mechanical System / Intake And Exhaust System / EGR cooler

Components

  1. EGR cooler
  2. EGR cooler hose A
  3. EGR cooler outlet hose
  4. EGR cooler gasket
  5. EGR valve gasket
  6. EGR valve

Removal and Installation

  1. Disconnect the negative battery terminal.
  2. Remove the engine cover.

(Refer to Engine and Transaxle Assembly - "Engine Cover")

  1. Remove the engine room under cover.

(Refer to Engine and Transaxle Assembly - "Engine Room Under Cover")

  1. Loosen the drain plug, and drain the engine coolant.

(Refer to Cooling System - "Coolant")

  1. Remove the front muffler

(Refer to Intake And Exhaust System - "Muffler")

  1. Remove the air cleaner assembly

(Refer to Intake and Exhaust System - "Air Cleaner")

  1. Remove the catalytic converter (WCC).

(Refer to Intake And Exhaust System - "Exhaust Manifold")

  1. Disconnect the wiring protector (A) and extension wiring connector (B).

  1. Disconnect the intercooler inlet hose (A).

Tightening torque : Clamp bolt: 4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb-ft)

WARNING

WARNING

Insert the hose until it reaches the end of stopper.

  1. Remove the resonator assembly and intercooler pipe (A).

Tightening torque : Mounting bolt : 18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)

WARNING

WARNING

When disconnecting the resonator assembly, pull the quick connector clamp in the direction of the arrow as below.

  • When installing the intercooler inlet hose, Match the alignment marks.
  • Insert the hose until it reaches the end of stopper.
  1. Remove the turbo charger water inlet hose & pipe (A).

Tightening torque : Eye bolt : 34.3 - 39.2 N.m (3.5 - 4.0 kgf.m, 25.3 - 28.9 lb-ft)

WARNING

WARNING

When installing, replace with a new eye bolt gasket

  1. Disconnect the EGR water outet hose (A).

  1. Disconnect the EGR water hose (A).

  1. Disconnect the EGR gas hose (A).

  1. Remove the EGR cooler & valve (A).

Tightening torque : 18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)

WARNING

WARNING

When installing the EGR cooler tighten the bolts with specified torque in the sequence shown.

  1. Install in the reverse order of removal.
  2. Fill the radiator with coolant.

(Refer to Cooling system - "Coolant")

WARNING

The coolant must be injected according to the integrated thermal management module (ITM) coolant filling method.

  1. Start engine and check for leaks.

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