EGR VALVE REMOVAL

PROCEDURE


  1. DRAIN ENGINE COOLANT

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  2. REMOVE DIESEL THROTTLE BODY ASSEMBLY

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  3. REMOVE WATER HOSE SUB-ASSEMBLY


    1. w/ Rear Air Conditioning System:


      1. B001FFC

        Slide the 2 clamps and disconnect the 2 water hoses from the water pipe.

      2. Slide the 2 clamps and disconnect the 2 water hoses from the air conditioning unit assembly.

      3. Slide the 2 clamps and disconnect the 2 water hoses from the No. 2 water by-pass pipe.

    2. w/o Rear Air Conditioning System:


      1. B001I2M

        Slide the 2 clamps and disconnect the 2 water hoses from the air conditioning unit assembly.

      2. Slide the 2 clamps and disconnect the 2 water hoses from the No. 2 water by-pass pipe.

  4. REMOVE NO. 2 WATER BY-PASS PIPE


    1. B001E0X

      Slide the clamp and disconnect the No. 13 water by-pass hose from the water outlet sub-assembly.

    2. Slide the clamp and disconnect the No. 15 water by-pass hose from the water by-pass pipe.

    3. Slide the clamp and disconnect the No. 16 water by-pass hose from the No. 1 EGR cooler.

    4. Remove the 3 bolts and No. 2 water by-pass pipe from the cylinder head cover sub-assembly, No. 3 water by-pass pipe sub-assembly and No. 2 engine cover bracket.

  5. REMOVE GAS FILTER


    1. B001EX0

      Disconnect the 2 vacuum hoses from the turbo pressure sensor and intake manifold.

    2. Remove the gas filter from the gas filter bracket.

  6. REMOVE DIESEL TURBO PRESSURE SENSOR


    1. B001F1B

      Disconnect the connector from the turbo pressure sensor.

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

  7. REMOVE NO. 3 ENGINE COVER BRACKET


    1. Remove the 2 bolts and No. 3 engine cover bracket from the engine cover bracket and No. 2 engine cover bracket.

  8. REMOVE NO. 2 ENGINE COVER BRACKET


    1. B001EUD

      Remove the 2 bolts and No. 2 engine cover bracket from the No. 3 water by-pass pipe sub-assembly and No. 2 EGR valve assembly.

  9. DISCONNECT UREA TANK FILLER PIPE ASSEMBLY (w/ Urea SCR System)


    1. B001FZG

      Remove the 2 bolts and disconnect the urea tank filler pipe assembly from the No. 1 oil reservoir bracket assembly.

  10. DISCONNECT VANE PUMP OIL RESERVOIR SUB-ASSEMBLY


    1. B001DHE

      Remove the 3 bolts and disconnect the vane pump oil reservoir sub-assembly from the body.

  11. DISCONNECT ENGINE WIRE


    1. B001EBY

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

    2. B001CGF

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

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

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

    5. Disconnect the camshaft position sensor.

    6. 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. Detach the clamp and remove the bolt.

    11. B001CPW

      Detach the clamp and disconnect the 2 connectors from the vane pump assembly.

    12. Detach the clamp and remove the bolt.

    13. Disconnect the 2 connectors from the 2 vacuum control valve sets.

  12. REMOVE EGR VALVE BRACKET


    1. B001E3F

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

  13. REMOVE NO. 2 EGR PIPE


    1. B001CAM

      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.

  14. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. B001H3S

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

    2. B001FPU

      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.

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


    1. B001EXQ

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

    2. B001DBQ

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

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


    1. B001CXD

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

  17. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY


    1. B001DUL

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

    2. B001FH0

      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. B001GM1

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

  18. REMOVE VACUUM CONTROL VALVE SET

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


    1. B001INR

      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. B001F5G

      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. B001E2I

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

    2. Remove the gasket.

    3. B001CRS

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