EGR VALVE REMOVAL


  1. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator cap sub-assembly while the engine assembly and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Connect a hose with an inside diameter of 9 mm (0.354 in.) to the radiator drain cock.

    2. Loosen the radiator drain cock plug.

      A003DK2E03
      Text in Illustration
      *1 Bleeder Plug *2 Radiator Cap Sub-assembly
      *3 Radiator Reserve Tank Assembly *4 Cylinder Block Drain Cock Plug
      *5 Radiator Drain Cock Plug - -

    3. Remove the radiator cap sub-assembly.

    4. Loosen the cylinder block drain cock plug, and drain the engine coolant.

    5. Tighten the radiator drain cock plug.

    6. Tighten the cylinder block drain cock plug.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    7. Disconnect the hose from the radiator drain cock.

  2. REMOVE SEAT TRACK COVER LH


    1. A003B84

      Using a clip remover, remove the clip.

    2. Detach the claw and remove the seat track cover LH.

  3. REMOVE FRONT SEAT ASSEMBLY RH


    1. A003GD3

      Move the front seat assembly fully forward.

    2. Remove the 2 bolts on the rear side of the seat.

    3. Move the front seat assembly to the rearmost position.

    4. Remove the 2 bolts on the front side of the seat.

    5. Move the front seat assembly to the center of the seat slide rail. Set the seatback in the upright position.

    6. Disconnect the front seat inner belt assembly connector.

    7. Remove the front seat assembly.

  4. REMOVE FRONT DOOR SCUFF PLATE RH

  5. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Fold back the floor carpet.

    2. Remove the 5 bolts and engine service hole sub cover sub-assembly.

  6. REMOVE TRANSMISSION SERVICE HOLE COVER SUB-ASSEMBLY


    1. Remove the 2 seat belt anchor covers.

    2. A003GMV

      Remove the 2 bolts and disconnect the front center seat belt assembly RH and front center seat lap type belt assembly.

    3. Detach the clips and fold back the carpet.

    4. A003ANJ

      Remove the 4 bolts and transmission service hole cover sub-assembly from the body.

  7. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  8. REMOVE NO. 16 WATER BY-PASS HOSE


    1. A003E90

      Slide the 2 clamps and remove the No. 16 water by-pass hose from the No. 1 EGR cooler and No. 2 water by-pass pipe.

  9. REMOVE DIESEL TURBO PRESSURE SENSOR


    1. A003GP0

      Disconnect the connector from the diesel turbo pressure sensor.

    2. Remove the bolt and diesel turbo pressure sensor from the No. 3 water by-pass pipe sub-assembly.

  10. DISCONNECT ENGINE WIRE


    1. A003D6U

      Detach the 2 clamps and disconnect the 2 connectors from the turbocharger sub-assembly.

    2. Disconnect the connector from the camshaft position sensor.

    3. A003C4N

      Detach the clamp and disconnect the connector from the differential pressure sensor.

    4. Disconnect the 3 connectors from the exhaust gas temperature sensors.

    5. Disconnect the connector from the exhaust fuel addition injector assembly.

    6. A003E0F

      Disconnect the 4 connectors from the 4 injector assemblies.

    7. Disconnect the electric EGR control valve assembly.

    8. Disconnect the connector from the glow plug connector.

    9. Disconnect the connector from the sensor wire of common rail assembly.

    10. A003HRN

      Detach the 2 clamps and remove the 4 bolts.

    11. A003FBB

      Disconnect the connector from the swirl control valve.

    12. Disconnect the connector from the vacuum control valve set.

    13. Detach the 2 clamps and disconnect the engine wire from the engine assembly.

  11. REMOVE EGR VALVE BRACKET


    1. A003DYA

      Remove the bolt, nut and EGR valve bracket from the electric EGR control valve assembly and intake manifold.

  12. REMOVE NO. 2 EGR PIPE


    1. A003FA5

      Remove the bolt, 4 nuts and No. 2 EGR pipe from the electric EGR control valve assembly and intake manifold.

    2. Remove the 2 gaskets.

  13. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A003F4Z

      Detach the clamp and disconnect the connector from the common rail assembly.

    2. A003E8F

      Slide the clamp and disconnect the No. 9 water by-pass hose from the electric EGR control valve assembly.

    3. Remove the 2 bolts and electric EGR control valve assembly.

    4. Remove the gasket.

  14. REMOVE NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A003EH9

      Disconnect the No. 4 fuel hose from the No. 3 water by-pass pipe sub-assembly.

    2. A003ENI

      Slide the clamp and disconnect the No. 8 water by-pass hose from the No. 3 water by-pass pipe sub-assembly.

    3. Remove the 2 bolts and No. 3 water by-pass pipe sub-assembly from the No. 1 EGR cooler.

  15. DISCONNECT NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A003BTC

      Slide the clamp and disconnect the No. 7 water by-pass hose from the No. 1 EGR cooler.

    2. Slide the clamp and disconnect the water hose from the No. 2 EGR valve assembly.

    3. A003EOI

      Remove the 2 bolts and disconnect the No. 4 water by-pass pipe sub-assembly from the intake manifold.

  16. REMOVE EGR PIPE INSULATOR


    1. A003ALP

      Remove the 2 bolts and EGR pipe insulator from the cylinder head sub-assembly.

  17. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY


    1. A003DG1

      Remove the bolt and disconnect the No. 1 EGR pipe sub-assembly from the vacuum transmitting pipe sub-assembly.

    2. A003B1N

      Remove the 4 nuts and the No. 1 EGR pipe sub-assembly from the exhaust manifold and EGR valve adapter.

    3. Remove the 2 gaskets.

    4. A003C6J

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold.

  18. REMOVE VACUUM CONTROL VALVE SET


    1. Disconnect the connector from the vacuum control valve set.

    2. A003HOH

      Disconnect the 2 vacuum hoses from the vacuum control valve set and No. 2 EGR valve assembly.

    3. A003EZH

      Remove the 2 bolts and vacuum control valve set from the intake manifold.

  19. REMOVE NO. 1 EGR COOLER WITH NO. 2 EGR VALVE ASSEMBLY


    1. A003E9R

      Remove the 4 bolts and No. 1 EGR cooler with No. 2 EGR valve assembly from the intake manifold.

  20. REMOVE EGR VALVE ADAPTER


    1. A003CN0

      Remove the 2 bolts and EGR valve adapter from the No. 2 EGR valve assembly.

    2. Remove the gasket.

  21. REMOVE NO. 2 EGR VALVE ASSEMBLY


    1. A003BXL

      Remove the 4 bolts and No. 2 EGR valve assembly from the No. 1 EGR cooler.

    2. Remove the gasket.

    3. A003EIM

      Using an E8 "TORX" socket wrench, remove the 4 stud bolts from the No. 2 EGR valve assembly.