EGR VALVE REMOVAL


  1. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  2. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)


    1. A003VJD

      Disengage the 2 claws and remove the No. 1 heater air duct splash shield seal.

  3. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)


    1. A003Z14

      Disengage the 2 claws and remove the No. 1 heater air duct splash shield seal.

  4. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)


    1. A003Y4M

      Disengage the claw and guide, and remove the No. 2 heater air duct splash shield seal.

  5. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)


    1. A003WN3

      Disengage the claw and guide, and remove the No. 2 heater air duct splash shield seal.

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


    1. A003WMR

      Remove the 2 bolts and cowl body mounting reinforcement LH.

  7. REMOVE COWL BODY MOUNTING REINFORCEMENT RH (for RHD)


    1. A003YWK

      Remove the 2 bolts and cowl body mounting reinforcement RH.

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


    1. A003W0I

      Disengage the clamp and separate the wire harness.

    2. A003WSZ

      w/ Wiper Deicer:

      Disengage the 3 clamps, disconnect the connector and separate the wire harness.

    3. A003YRF

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

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


    1. A003X05

      Disengage the clamp and separate the wire harness.

    2. A003X62

      w/ Wiper Deicer:

      Disengage the 3 clamps, disconnect the connector and separate the wire harness.

    3. A003ZGV

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

  10. DRAIN COOLANT (for Engine)

    Note

    Do not remove the reserve 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. A003Z8O

      Loosen the radiator drain cock plug.

      Tech Tips

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

    2. Remove the reserve tank cap and drain the coolant.

      A003ZHYE01
      Text in Illustration
      *1 Reserve Tank Cap *2 Radiator Drain Cock Plug

  11. REMOVE NO. 2 CYLINDER HEAD COVER


    1. A003WMME01

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

      Note


      • Disengage the clips in the order shown in the illustration.

      • When disengaging clip 3, hold the end of the cover behind clip 3 and lift the cover straight up.

      • 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 or pull it up by holding the left and right ends may cause the cover to break.

  12. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A003ZFN

      Disconnect the connector and wire harness clamp.

    2. A003XA5

      Disconnect the water hose from the clamp.

    3. Disengage the 2 clamps and remove the air cleaner cap sub-assembly.

    4. Loosen the hose clamp and disconnect the air cleaner hose assembly.

  13. REMOVE INLET AIR CLEANER ASSEMBLY


    1. A003VRO

      Separate the water hose from the hose clamp.

    2. A003VGC

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

    3. Remove the 2 bolts, 2 clips and inlet air cleaner assembly.

  14. REMOVE AIR CLEANER CASE


    1. Remove the air cleaner filter element sub-assembly from the air cleaner case.

    2. A003VMR

      Disconnect the water hose from the clamp.

    3. Remove the 2 bolts and air cleaner case.

  15. REMOVE EGR PIPE ASSEMBLY


    1. A003XYD

      Disconnect the 2 wire harness clamps.

    2. A003YI1

      Remove the bolt and wire harness support.

    3. A003YX6

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

  16. REMOVE EGR VALVE ASSEMBLY


    1. A003WCO

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

    2. A003WD3E01
      Text in Illustration
      *1 Stud Bolt and Nut

      Remove the 4 nuts and bolt.

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

    4. Remove the gasket.

    5. A003ZIH

      Remove the 2 nuts, EGR valve assembly and gasket.

  17. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A003VBV

      Remove the bolt and wire harness clamp bracket.