EGR VALVE (w/o EGR Cooler) REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

  2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A01DYO3

      Remove the 3 bolts, 2 nuts and cover.

  3. REMOVE CHARGE AIR COOLER ASSEMBLY


    1. A01E2UO

      Disconnect the diesel turbo IAT sensor connector.

    2. Loosen the 2 hose clamps of the No. 1 air hose.

    3. A01DXAO

      Loosen the 2 hose clamps of the No. 2 air hose.

    4. A01DYHX

      Remove the 4 bolts and CAC.

    5. A01E1NN

      Using a 22 mm deep socket wrench, remove the IAT sensor.

      Tech Tips

      Replace the IAT sensor if it is deformed, cracked or malfunctioning. It is not necessary to replace the IAT sensor each time the CAC is replaced.

    6. A01E0PG

      Remove the 4 bolts, intake air connector and gasket.

  4. REMOVE VACUUM SWITCHING VALVE BRACKET


    1. A01DWGJ

      Disconnect the 2 connectors.

    2. Disconnect the vacuum hoses from the 3 locations.

    3. Remove the 2 bolts and bracket.

  5. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A01DZU2

      Disconnect the 2 connectors.

    2. A01E2KU

      Remove the 2 bolts, 2 nuts, throttle body and gasket.

  6. REMOVE THROTTLE BODY BRACKET


    1. A01E1XR

      Remove the 3 bolts and bracket.

  7. REMOVE INTAKE AIR CONNECTOR


    1. Remove the 2 nuts, bolt, air connector and bracket.

  8. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

    A01DYONE01

    1. Remove the 2 bolts, 2 nuts, pipe and 2 gaskets.

  9. REMOVE EGR VALVE ASSEMBLY


    1. Remove the EGR valve and gasket.