EGR VALVE(w/o EGR Cooler) REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the EGR valve removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedures Effects/Inoperative when not Performed Link
Replacement of diesel throttle body assembly Perform initialization -

Click here

Replacement of electric EGR control valve assembly Perform initialization -

Click here

CAUTION:

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

B0068EY

PROCEDURE


  1. DRAIN ENGINE COOLANT

    Click here

  2. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  3. REMOVE NO. 2 WATER BY-PASS PIPE

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.


    1. B0024QWC01
      *1 No. 13 Water By-pass Hose
      *2 No. 15 Water By-pass Hose
      *3 Heater Hose
      *4 No. 16 Water By-pass Hose

      Slide the clamp and disconnect the No. 2 water by-pass pipe from the No. 13 water by-pass hose.

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

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

    4. Slide the clamp and disconnect the No. 16 water by-pass hose from the EGR pipe stay.

    5. Remove the 4 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.

  4. REMOVE GAS FILTER


    1. B0028QH

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

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

  5. REMOVE TURBO PRESSURE SENSOR


    1. B0025UW

      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.

  6. REMOVE NO. 2 HOSE TO HOSE TUBE


    1. B002482

      Slide the clamp to disconnect the union to connector tube hose from the No. 1 hose to hose tube.

    2. Slide the clamp to disconnect the union to check valve hose from the vacuum pump assembly.

    3. Remove the 2 bolts and No. 2 hose to hose tube from the cylinder head cover sub-assembly and hose bracket.

  7. REMOVE NO. 2 ENGINE COVER BRACKET


    1. B0028C0

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

  8. DISCONNECT FUEL FILTER ASSEMBLY


    1. B0027DON01

      Disconnect the clamp and slide the lead wire as shown in the illustration to remove it.

    2. B0028V8

      Disconnect the fuel filter assembly from the fuel filter support.

  9. DISCONNECT ENGINE WIRE


    1. B0028U6

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

    2. B002826

      Disconnect the connector from the camshaft position sensor.

    3. Disconnect the 4 connectors from the 4 injector assemblies.

    4. Disconnect the connector from the electric EGR control valve assembly.

    5. Disconnect the connector from the glow plug connector.

    6. Disconnect the connector from the sensor wire of common rail assembly.

    7. Detach the clamp and remove the bolt.

    8. B0025KX

      Detach the clamp and disconnect the connector from the power steering oil pressure switch.

    9. Remove the bolt and disconnect the engine wire.

  10. REMOVE EGR VALVE BRACKET

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.


    1. B0028CU

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

  11. REMOVE NO. 2 EGR PIPE

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.


    1. B0025N0

      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.

  12. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.


    1. B0026O8

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

    2. B0028AD

      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 from the EGR valve adapter sub-assembly.

    4. Remove the gasket.