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 engine 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. REMOVE AIR TUBE SUB-ASSEMBLY LH

    Click here

  16. REMOVE NO. 1 GAS FILTER


    1. B001ASH

      Disconnect the hose from the intake pipe.

    2. Remove the No. 1 gas filter.

  17. REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET


    1. B0018SG

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

  18. REMOVE DIESEL THROTTLE BODY ASSEMBLY LH

    Click here

  19. REMOVE NO. 1 AIR HOSE

    Click here

  20. REMOVE NO. 3 AIR TUBE

    Click here

  21. REMOVE NO. 2 AIR HOSE

    Click here

  22. REMOVE NO. 4 AIR TUBE

    Click here

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

    Click here

  24. DISCONNECT WATER HOSE SUB-ASSEMBLY

    Click here

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

    Click here

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

    Click here

  27. DISCONNECT FUEL HOSE

    Click here

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

    Click here

  29. REMOVE NO. 4 WATER BY-PASS PIPE

    Click here

  30. DISCONNECT ENGINE WIRE

    Click here

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

    Click here

  32. REMOVE NO. 6 INJECTION PIPE SUB-ASSEMBLY

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

  37. REMOVE INJECTION PIPE LH

    Click here

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

    Click here

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

    Click here

  40. DISCONNECT CONNECTING WIRE (w/ DPF)

    Click here

  41. REMOVE COMMON RAIL ASSEMBLY LH

    Click here

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

    Click here

  43. DISCONNECT FUEL PUMP MOTOR WIRE

    Click here

  44. REMOVE NO. 5 INJECTION PIPE SUB-ASSEMBLY

    Click here

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

    Click here

  46. REMOVE INJECTION PIPE RH

    Click here

  47. REMOVE COMMON RAIL ASSEMBLY RH

    Click here

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

    Click here

  49. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR

    Click here

  50. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR

    Click here

  51. REMOVE NO. 4 EGR PIPE


    1. B0018IN

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

  52. REMOVE INTAKE PIPE


    1. B0019W9

      Remove the 4 bolts, 2 nuts and intake pipe.

    2. Remove the gasket.

  53. DISCONNECT NO. 2 ENGINE WIRE

    Click here

  54. REMOVE NO. 3 INTAKE MANIFOLD

    Click here

  55. REMOVE INTAKE MANIFOLD INSULATOR

    Click here

  56. REMOVE EGR PIPE INSULATOR

    Click here

  57. DISCONNECT NO. 5 WATER BY-PASS PIPE


    1. B0019Z9

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

  58. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY


    1. B001AQ3

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

  59. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY


    1. B0018S5

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

  60. REMOVE EGR VALVE ASSEMBLY WITH EGR COOLER


    1. B001B4SE03
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 6 bolts and EGR valve with EGR cooler.

  61. REMOVE NO. 3 EGR PIPE


    1. B001B3GE03
      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.

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


    1. B0018ZD

      Remove the No. 9 water by-pass hose.

    2. Disconnect the 2 water hoses.

  63. REMOVE NO. 1 EGR VALVE ASSEMBLY

  64. REMOVE NO. 2 EGR VALVE ASSEMBLY

  65. REMOVE EGR COOLER GASKET