EGR VALVE REMOVAL

PROCEDURE

1. DRAIN ENGINE COOLANT

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2. REMOVE WINDSHIELD WIPER MOTOR AND LINK

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3. REMOVE FRONT NO. 1 VENTILATOR SEAL

   
   

   • for LHD:

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   • for RHD:

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4. REMOVE FRONT AIR SHUTTER SEAL RH

   
   

   • for LHD:

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   • for RHD:

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5. REMOVE INNER COWL TOP TO COWL BRACE

   
   

   • for LHD:

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   • for RHD:

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6. REMOVE OUTER COWL TOP PANEL

   
   

   • for LHD:

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   • for RHD:

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7. REMOVE NO. 1 ENGINE COVER

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8. REMOVE NO. 3 WATER BY-PASS HOSE

   
   

   1. 

      Slide the 2 hose clips and disconnect the No. 3 water by-pass hose from the EGR valve assembly and EGR cooler assembly.

   2. Disengage the clamp to remove the No. 3 water by-pass hose from the hose clamp.

9. DISCONNECT NO. 2 WATER BY-PASS HOSE

   
   

   1. 

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

10. REMOVE EGR VALVE BRACKET (for LHD)

    
    

    1. 

       Disconnect the EGR valve assembly connector.

    2. Disconnect the purge valve (purge VSV) connector.

    3. Disengage the 4 clamps to separate the wire harness from the intake manifold.

    4. 

       Remove the 2 bolts, 2 nuts and EGR valve bracket from the EGR valve assembly, EGR cooler assembly, camshaft housing sub-assembly and timing chain cover assembly.

11. REMOVE EGR VALVE BRACKET (for RHD)

    
    

    1. 

       Disconnect the EGR valve assembly connector.

    2. Disconnect the purge valve (purge VSV) connector.

    3. Disengage the 3 clamps to separate the wire harness from the intake manifold.

    4. 

       Remove the 2 bolts, 2 nuts and EGR valve bracket from the EGR valve assembly, EGR cooler assembly, camshaft housing sub-assembly and timing chain cover assembly.

12. REMOVE EGR VALVE ASSEMBLY

    
    

    1. 

       Remove the 4 nuts.

    2. 

       Using "TORX" socket wrench E6, remove the 2 stud bolts and EGR valve assembly from the EGR cooler assembly and intake manifold.

    3. 

       Remove the EGR inlet gasket from the intake manifold.

13. REMOVE EGR VALVE GASKET

    
    

    1. 

       Remove the EGR valve gasket from the EGR valve assembly.