EGR VALVE REMOVAL


  1. DRAIN COOLANT (for Engine)

    Note

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


    1. Loosen the radiator drain cock plug.

    2. Remove the radiator cap sub-assembly.

      A01I4G4E01
      Text in Illustration
      *1 Radiator Cap Sub-assembly *2 Radiator Drain Cock Plug

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

  2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A01I4EV

      Lift the rear of the No. 1 engine cover sub-assembly to detach the No. 1 engine cover sub-assembly from the 2 pins, and then lift the front of the No. 1 engine cover sub-assembly to detach the No. 1 engine cover sub-assembly from the pin and remove the No. 1 engine cover sub-assembly.

      Note

      Attempting to disengage both front and rear pins at the same time may cause the No. 1 engine cover sub-assembly to break.

  3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A01I34Q

      Disconnect the mass air flow meter connector and wire harness clamp from the air cleaner cap sub-assembly.

    2. Disconnect the ventilation hose from the cylinder head cover.

    3. Disconnect the connector and wire harness clamp.

    4. A01I2EB

      Release the 2 clamps and remove the air cleaner cap sub-assembly.

    5. A01I32VE01
      Text in Illustration
      *1 Retainer
      *2 Fuel Tube Connector
      *3 Pipe
      *4 O-ring
      *a Pinch
      *b Pull

      Disconnect the 2 fuel vapor feed hoses.

      Note


      • Remove any dirt or foreign matter on the fuel tube connector before performing this work.

      • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has an O-ring that seals the pipe.

      • Perform this work by hand. Do not use any tools.

      • Protect the disconnected parts by covering them with plastic bags after disconnecting each fuel vapor feed hose.

    6. A01I3VF

      Loosen the hose clamp and disconnect the air cleaner hose from the throttle with motor body assembly.

  4. REMOVE EGR VALVE ASSEMBLY


    1. A01I2H1

      Disconnect the EGR valve assembly connector.

    2. A01I5L5

      Slide the 2 clips and disconnect the 2 water by-pass hoses from the EGR valve assembly.

    3. A01I5HY

      Using a 10 mm deep socket wrench, remove the bolt from the EGR valve assembly.

    4. Using a 12 mm deep socket wrench, remove the 2 nuts from the EGR valve assembly.

    5. A01I4A7

      Remove the 3 bolts and EGR valve assembly from the intake manifold.

    6. A01I2BB

      Remove the 2 gaskets from the intake manifold and No. 1 EGR pipe.