EGR VALVE REMOVAL


  1. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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


    1. A003TIT

      Remove the 3 bolts and cowl body mounting reinforcement LH.

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


    1. A003UFL

      Remove the 3 bolts and cowl body mounting reinforcement LH.

  4. REMOVE OUTER COWL TOP PANEL (for LHD)


    1. A003S9NE01
      Text in Illustration
      *1 No. 1 Heater Air Duct Splash Shield Seal
      *2 Water Guard Plate RH

      Disengage each claw of the No. 1 heater air duct splash shield seal and water guard plate RH, and bend them.

    2. A003SJJ

      Disengage the clamp and separate the wire harness.

    3. Remove the 8 bolts, nut and outer cowl top panel.

  5. REMOVE OUTER COWL TOP PANEL (for RHD)


    1. A003RYXE01
      Text in Illustration
      *1 Water Guard Plate RH
      *2 No. 1 Heater Air Duct Splash Shield Seal

      Disengage each claw of the water guard plate RH and No. 1 heater air duct splash shield seal, and bend them.

    2. A003UWL

      Disengage the clamp and separate the wire harness.

    3. Remove the 8 bolts, nut and outer cowl top panel.

  6. DRAIN COOLANT (for Engine)

    Note

    Do not remove the reservoir tank cap 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. Remove the reservoir tank cap.

      A003UP5E01
      Text in Illustration
      *1 Reservoir Tank Cap *2 Radiator Drain Cock Plug
      *3 Air Release Valve (w/ Air Release Valve) - -

    2. 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.

  7. REMOVE NO. 2 CYLINDER HEAD COVER


    1. A003S7G

      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.

  8. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A003RKT

      Disconnect the mass air flow meter connector.

    2. A003TOZE01

      Release the 2 clamps.

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

  9. REMOVE INLET AIR CLEANER ASSEMBLY


    1. A003TOE

      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. A003SAW

      Separate the hose from the 3 hose clamps.

    3. Remove the 3 bolts and air cleaner case.

  11. REMOVE EGR PIPE ASSEMBLY


    1. A003SHC

      Disconnect the 2 wire harness clamps.

    2. A003U8S

      Remove the bolt and wire harness support.

    3. A003TVM

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

  12. REMOVE EGR VALVE ASSEMBLY


    1. A003SPT

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

    2. A003TUGE01
      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. A003SJV

      Remove the 2 nuts, EGR valve assembly and gasket.

  13. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A003T5I

      Remove the bolt and wire harness clamp bracket.