EGR VALVE REMOVAL

CAUTION / NOTICE / HINT

Note


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

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

PROCEDURE


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    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.

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

  2. REMOVE FRONT BUMPER LOWER COVER

    Click here

  3. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (w/ EGR Cooler)

    Click here

  4. DRAIN ENGINE COOLANT (w/ EGR Cooler)

    Click here

  5. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. Remove the cowl top ventilator louver Click here.

  6. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. Remove the diesel throttle body Click here.

  7. DISCONNECT NO. 3 WATER BY-PASS HOSE (w/ EGR Cooler)


    1. B001HKO

      Remove the clamp.

    2. Disconnect the No. 3 water by-pass hose from the EGR cooler.

  8. DISCONNECT NO. 4 WATER BY-PASS HOSE (w/ EGR Cooler)


    1. Disconnect the No. 4 water by-pass hose from the EGR cooler.

  9. REMOVE INJECTION PIPE

    Note


    • After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.

    • After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating the injector inlet.


    1. B001I5L

      Remove the 2 nuts and No. 3 injection pipe clamp.

    2. B001CIR

      Remove the 2 bolts and 2 No. 2 injection pipe clamps.

    3. B001HJ0E01
      Text in Illustration
      *a for Injector Side
      *b for Common Rail Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

  10. REMOVE AIR CONNECTOR STAY


    1. B001GOG

      Remove the 3 bolts and air connector stay.

  11. DISCONNECT ENGINE WIRE (for LHD)


    1. B001CC8

      Remove the 2 bolts.

    2. Detach the clamp and disconnect the engine wire.

  12. DISCONNECT ENGINE WIRE (for RHD)


    1. B001DI8

      Remove the bolt and disconnect the engine wire.

  13. REMOVE EGR VALVE BRACKET


    1. Remove the 2 nuts and EGR valve bracket.

  14. REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY


    1. B001FO9

      Disconnect the 2 connectors from the electric EGR control valve and E-VRV.

    2. B001GBC

      Detach the wire harness clamp.

    3. B001GPL

      Disconnect the 5 vacuum hoses.

    4. Remove the bolt and gas filter together with the gas filter bracket.

    5. B001F01

      Remove the 2 bolts and E-VRV bracket together with the EGR vacuum damper.

  15. REMOVE NO. 2 INTAKE AIR CONNECTOR


    1. B001CUB

      Remove the 3 nuts, No. 2 intake air connector and gasket.

  16. REMOVE INTAKE AIR CONNECTOR


    1. B001FSZ

      Remove the 3 bolts, intake air connector and 2 gaskets.

  17. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER (w/ EGR Cooler)


    1. B001FY2

      Disconnect the No. 3 vacuum transmitting hose from the No. 2 EGR valve.

    2. B001HK8

      Remove the bolt, 2 nuts, electric EGR control valve together with the No. 2 EGR valve and EGR cooler.

    3. Remove the gasket from the cylinder block.

  18. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 1 EGR PIPE SUB-ASSEMBLY (w/o EGR Cooler)


    1. B001GAR

      Remove the 2 nuts and electric EGR control valve together with the No. 1 EGR pipe and gasket.

  19. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. B001I1CE01
      Text in Illustration
      *A w/ EGR Cooler
      *B w/o EGR Cooler

      Remove the 2 bolts, electric EGR control valve and gasket.

  20. REMOVE EGR VALVE ADAPTER (w/ EGR Cooler)


    1. B001CE3

      Using a 6 mm hexagon wrench, remove the 3 hexagon bolts, 3 plate washers, EGR valve adapter and gasket.

  21. REMOVE NO. 2 EGR VALVE ASSEMBLY (w/ EGR Cooler)


    1. B001HI4

      Using a 5 mm hexagon wrench, remove the hexagon bolt, No. 2 EGR valve and gasket.