EGR VALVE (w/o DPF) REMOVAL

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.


  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


    1. Remove the clip, 5 bolts and front bumper lower cover.

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


    1. Remove the 4 bolts and No. 1 engine under cover.

  4. DRAIN ENGINE COOLANT (w/ EGR Cooler)

    CAUTION:

    Do not remove the radiator cap 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.

      Tech Tips

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

    2. A00JWDE

      Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.

    3. Loosen the cylinder block drain cock plug.

      A00JVX9E01
      Text in Illustration
      *1 Radiator Reservoir *2 Vent Plug
      *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug

  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. A00O5VY

      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. A00OABQ

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

    2. A00O7DG

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

    3. A00O5DME01
      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. A00OBBG

      Remove the 3 bolts and air connector stay.

  11. DISCONNECT ENGINE WIRE (for LHD)


    1. A00O8K9

      Remove the 2 bolts.

    2. Detach the clamp and disconnect the engine wire.

  12. DISCONNECT ENGINE WIRE (for RHD)


    1. A00O4X0

      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. A00O80I

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

    2. A00OBI1

      Detach the wire harness clamp.

    3. A00O7TG

      Disconnect the 5 vacuum hoses.

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

    5. A00OAZB

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

  15. REMOVE NO. 2 INTAKE AIR CONNECTOR


    1. A00O5AR

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

  16. REMOVE INTAKE AIR CONNECTOR


    1. A00O5UZ

      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. A00O9MU

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

    2. A00O8J1

      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. A00OB8D

      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. A00O45CE01
      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. A00O3K9

      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. A00O4MP

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