EGR VALVE REMOVAL


  1. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    1. Remove the windshield wiper motor and link assembly Click here.

  2. REMOVE COWL BODY MOUNTING REINFORCEMENT LH (for LHD)


    1. A01JAL3

      Remove the 3 bolts and cowl body mounting reinforcement LH.

  3. REMOVE COWL BODY MOUNTING REINFORCEMENT LH (for RHD)


    1. A01JDA9

      Remove the 3 bolts and cowl body mounting reinforcement LH.

  4. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)


    1. A01JCF9

      Disengage the clamp and separate the wire harness.

    2. A01J9NS

      Disengage the claw and bend the No. 1 heater air duct splash shield seal.

    3. A01JC64

      Disengage the claw and bend the water guard plate RH.

    4. A01J9P5

      Remove the 9 bolts and outer cowl top panel sub-assembly.

  5. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)


    1. A01JAH2

      Disengage the clamp and separate the wire harness from the outer cowl top panel sub-assembly.

    2. A01JB4QE01

      Disengage the clamp*1 and disconnect the connector (w/ Windshield Deicer).

    3. Disengage the clamp*2 and separate the wire harness from the outer cowl top panel sub-assembly.

    4. A01J9F7

      Disengage the claw and bend the No. 1 heater air duct splash shield seal.

    5. A01JBZC

      Disengage the claw and bend the water guard plate RH.

    6. A01J9HT

      Remove the 9 bolts and outer cowl top panel sub-assembly.

  6. DRAIN COOLANT (for Engine)

    Note

    Do not remove the reservoir tank cap, cylinder block drain cock plugs and radiator drain cock plug 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 and drain the coolant.

      Tech Tips

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

    2. Loosen the cylinder block drain cock plug.

      Tech Tips

      The plug is on the back of the generator on the exhaust manifold side.

      A01JB2ZE01
      Text in Illustration
      *1 Reservoir Tank Cap *2 Cylinder Block Drain Cock Plug
      *3 Radiator Drain Cock Plug *4 Air Release Valve

  7. REMOVE NO. 2 CYLINDER HEAD COVER


    1. A01JAJ9

      Remove the 3 clips and No. 2 cylinder head cover.

      Note


      • Attempting to disengage both front and rear clips at the same time may cause the cover to break.

      • Pull the cover straight up to remove. Attempting to pull the cover forward may cause it to break.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the cover to break.

  8. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A01JAMH

      Disconnect the mass air flow meter connector.

    2. A01J8QWE01

      Release the 2 clamps.

    3. Loosen the hose clamp and remove the air cleaner cap.

  9. REMOVE INLET AIR CLEANER ASSEMBLY


    1. A01JBG6

      Separate the hose from the hose clamp.

    2. Separate the wire harness clamp from the inlet air cleaner assembly.

    3. Remove the 3 bolts and inlet air cleaner assembly.

  10. REMOVE AIR CLEANER CASE


    1. Remove the air cleaner filter element.

    2. A01JCW8

      Separate the hose from the 3 hose clamps.

    3. Remove the 3 bolts and air cleaner case.

  11. REMOVE EGR PIPE ASSEMBLY


    1. A01J9BB

      Disconnect the 2 wire harness clamps.

    2. A01JALE

      Remove the bolt and wire harness support.

    3. A01JCSG

      Remove the 4 bolts, EGR pipe assembly and 2 gaskets.

  12. REMOVE EGR VALVE ASSEMBLY


    1. A01J9SR

      Disconnect the connector, wire harness clamp and 4 water hoses.

    2. A01JC2YE01
      Text in Illustration
      *1 Stud Bolt and Nut

      Remove the 4 nuts and bolt.

    3. Using an E8 "TORX" wrench, remove the 4 stud bolts and EGR valve with cooler assembly.

    4. Remove the gasket.

    5. A01JAWD

      Remove the 2 nuts, EGR valve assembly and gasket.

  13. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A01J92F

      Remove the bolt and wiring harness clamp bracket.