EGR VALVE REMOVAL

PROCEDURE


  1. DRAIN ENGINE COOLANT (for Engine)

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  2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

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  3. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

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  4. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

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  5. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

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  6. REMOVE FUEL PUMP PROTECTOR

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  7. REMOVE EGR PIPE CONNECTOR

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  8. REMOVE NO. 2 EGR PIPE

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  9. DISCONNECT ENGINE WIRE


    1. A01W29PE02
      Text in Illustration
      *a Fuel Pump Sub-assembly Connector
      *b Ignition Coil Assembly Connector
      *c Camshaft Position Sensor Connector
      B001O8N Bolt
      B001OAO Nut
      B001NW5 Connector

      Remove the 2 bolts and disconnect the 2 earth wires from the EGR valve bracket.

    2. Remove the nut.

    3. Disconnect the 2 camshaft position sensor connectors.

    4. Disconnect the ignition coil assembly connector.

    5. Disconnect the fuel pump sub-assembly connector.

    6. Disengage the clamp.

    7. A01W2OT

      Remove the bolt.

    8. Disconnect the engine coolant temperature sensor connector.

  10. REMOVE EGR VALVE WITH COOLER ASSEMBLY


    1. A01VZDT

      Disconnect the EGR valve assembly connector.

    2. A01W15C

      Remove the engine cover joint and separate the fuel hose bracket from the EGR valve bracket.

    3. A01W0N1

      Remove the 4 bolts and 2 EGR valve brackets.

    4. A01W5QG

      Disengage the water hose from the hose clamp.

    5. A01W503

      Slide the clip and disconnect the water hose sub-assembly from the EGR cooler assembly.

    6. A01W4MHE02
      Text in Illustration
      *1 No. 2 Water By-pass Hose
      *2 No. 3 Water By-pass Hose
      *3 No. 4 Water By-pass Hose

      Slide the clip and disconnect the No. 2 water by-pass hose from the EGR valve assembly.

    7. Slide the clip and disconnect the No. 3 water by-pass hose from the EGR cooler assembly.

    8. Slide the clip and disconnect the No. 4 water by-pass hose from the EGR cooler assembly.

    9. A01W2LF

      Remove the 2 nuts and EGR valve with cooler assembly from cylinder head sub-assembly.

    10. A01W2XO

      Remove the No. 2 EGR pipe gasket from the EGR valve assembly.

  11. REMOVE EGR VALVE ASSEMBLY


    1. A01W1PF

      Slide the clip and disconnect the No. 1 water by-pass hose from the EGR valve assembly.

    2. A01W3AB

      Remove the 2 nuts and EGR valve assembly from the EGR cooler assembly.

    3. A01W4SO

      Remove the EGR valve gasket from the EGR valve assembly.