EGR VALVE REMOVAL

CAUTION / NOTICE / HINT

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail, cylinder head, or intake manifold, it is necessary to replace the injection pipes with new ones.

  • w/ DPF:

    When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.


    1. Disconnect the cables from the negative (-) main battery and sub-battery terminals.

  3. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

    Click here

  4. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

    Click here

  5. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

    Click here

  6. REMOVE UPPER RADIATOR SUPPORT SEAL

    Click here

  7. DRAIN ENGINE COOLANT

    Click here

  8. REMOVE INTERCOOLER ASSEMBLY

    Click here

  9. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  10. REMOVE NO. 1 AIR CLEANER HOSE

    Click here

  11. REMOVE INTAKE AIR CONNECTOR

    Click here

  12. REMOVE NO. 2 ENGINE OIL DIPSTICK GUIDE

    Click here

  13. REMOVE AIR TUBE SUB-ASSEMBLY RH

    Click here

  14. REMOVE DIESEL THROTTLE BODY ASSEMBLY RH

    Click here

  15. DRAIN CLUTCH FLUID (for Manual Transmission)

  16. REMOVE CLUTCH HOSE (for Manual Transmission)

    Click here

  17. REMOVE AIR TUBE SUB-ASSEMBLY LH

    Click here

  18. REMOVE TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for Manual Transaxle)

    Click here

  19. REMOVE NO. 1 GAS FILTER


    1. B001YAL

      Disconnect the hose from the intake pipe.

    2. Remove the No. 1 gas filter.

  20. REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET


    1. B001WFF

      for Manual Transmission:


      1. Remove the bolt and disconnect the clutch tube to release cylinder 2 way from the No. 3 intercooler support bracket.

    2. B001YSQ

      Remove the 2 bolts and No. 3 intercooler support bracket.

  21. REMOVE DIESEL THROTTLE BODY ASSEMBLY LH

    Click here

  22. REMOVE NO. 1 AIR HOSE

    Click here

  23. REMOVE NO. 3 AIR TUBE

    Click here

  24. REMOVE NO. 2 AIR HOSE

    Click here

  25. REMOVE NO. 4 AIR TUBE

    Click here

  26. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY

    Click here

  27. DISCONNECT WATER HOSE SUB-ASSEMBLY

    Click here

  28. REMOVE HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)

    Click here

  29. REMOVE NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY

    Click here

  30. DISCONNECT FUEL HOSE

    Click here

  31. REMOVE NO. 3 WATER BY-PASS PIPE (w/o Viscous Heater)

    Click here

  32. REMOVE NO. 4 WATER BY-PASS PIPE

    Click here

  33. DISCONNECT ENGINE WIRE

    Click here

  34. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY (w/o DPF)

    Click here

  35. REMOVE NO. 6 INJECTION PIPE SUB-ASSEMBLY

    Click here

  36. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (w/ DPF)

    Click here

  37. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ DPF)

    Click here

  38. REMOVE CYLINDER HEAD COVER SILENCER LH (w/ DPF)

    Click here

  39. REMOVE NO. 4 NOZZLE LEAKAGE PIPE (w/ DPF)

    Click here

  40. REMOVE INJECTION PIPE LH

    Click here

  41. REMOVE NO. 2 FUEL PIPE (w/ DPF)

    Click here

  42. REMOVE NO. 5 NOZZLE LEAKAGE PIPE (w/ DPF)

    Click here

  43. DISCONNECT CONNECTING WIRE (w/ DPF)

    Click here

  44. REMOVE COMMON RAIL ASSEMBLY LH

    Click here

  45. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY

    Click here

  46. DISCONNECT FUEL PUMP MOTOR WIRE

    Click here

  47. REMOVE NO. 5 INJECTION PIPE SUB-ASSEMBLY

    Click here

  48. REMOVE CYLINDER HEAD COVER SILENCER RH (w/ DPF)

    Click here

  49. REMOVE INJECTION PIPE RH

    Click here

  50. REMOVE COMMON RAIL ASSEMBLY RH

    Click here

  51. REMOVE NO. 3 NOZZLE LEAKAGE PIPE (w/ DPF)

    Click here

  52. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR

    Click here

  53. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR

    Click here

  54. REMOVE NO. 4 EGR PIPE


    1. B001XID

      Remove the 4 bolts, No. 4 EGR pipe and 2 gaskets.

  55. REMOVE INTAKE PIPE


    1. B001WFN

      Remove the 4 bolts, 2 nuts and intake pipe.

    2. Remove the gasket.

  56. DISCONNECT NO. 2 ENGINE WIRE

    Click here

  57. REMOVE NO. 3 INTAKE MANIFOLD

    Click here

  58. REMOVE INTAKE MANIFOLD INSULATOR

    Click here

  59. REMOVE EGR PIPE INSULATOR

    Click here

  60. DISCONNECT NO. 5 WATER BY-PASS PIPE


    1. B00205R

      Remove the bolt and disconnect the 2 hoses to disconnect the No. 5 water by-pass pipe.

  61. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY


    1. B001Y8J

      Remove the 4 bolts, No. 1 EGR pipe and 2 gaskets.

  62. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY


    1. B001XFR

      Remove the 4 bolts, No. 2 EGR pipe and 2 gaskets.

  63. REMOVE EGR VALVE ASSEMBLY WITH EGR COOLER


    1. B001XV2E02
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 6 bolts and EGR valve with EGR cooler.

  64. REMOVE NO. 3 EGR PIPE


    1. B001YCGE02
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 4 nuts, 4 bolts and No. 3 EGR pipe.

    2. Remove the 2 gaskets.

    3. w/ DPF:

      Remove the O-ring from the No. 3 water by-pass pipe.

  65. REMOVE NO. 9 WATER BY-PASS HOSE AND WATER HOSE


    1. B001ZAY

      Remove the No. 9 water by-pass hose.

    2. Disconnect the 2 water hoses.

  66. REMOVE NO. 1 EGR VALVE ASSEMBLY

  67. REMOVE NO. 2 EGR VALVE ASSEMBLY

  68. REMOVE EGR COOLER GASKET