EGR VALVE (w/o EGR Cooler) REMOVAL


  1. PRECAUTION

    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.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  3. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  4. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY (w/ Intercooler)

    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 its injector inlet.


    1. w/ Intercooler:


      1. A01DWWA

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

      2. A01E1SS

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

      3. A01DXC6E01
        Text in Illustration
        *a Injector Side
        *b 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.

    2. w/o Intercooler:


      1. A01DXPXE02
        Text in Illustration
        *1 No. 2 Injection Pipe Clamp
        *2 No. 3 Injection Pipe Clamp
        *a Injector Side
        *b Common Rail Side

        Remove the bolt and No. 2 injection pipe clamp.

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

      3. Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

  5. REMOVE NO. 2 INTAKE AIR CONNECTOR BRACKET


    1. A01DVDTE01
      Text in Illustration
      *A w/ Intercooler
      *B w/o Intercooler
      *1 No. 2 Intake Air Connector Bracket
      *2 Intake Air Connector

      Remove the 3 bolts and No. 2 intake air connector bracket.

  6. REMOVE INTAKE AIR CONNECTOR (w/o Intercooler)


    1. Remove the 2 nuts, bolt, intake air connector and gasket.

  7. REMOVE NO. 3 WATER BY-PASS PIPE (w/ Intercooler)


    1. A01DZCR

      Remove the 2 bolts and disconnect the No. 3 water by-pass pipe with the wire harness.

  8. REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (for EGR)


    1. w/ Intercooler:


      1. A01DZHP

        Disconnect the 2 connectors.

      2. A01E31V

        Disconnect the 6 vacuum hoses.

      3. Remove the bolt and No. 1 gas filter with gas filter bracket.

      4. A01DY7U

        Remove the 2 bolts and electric vacuum regulating valve.

    2. w/o Intercooler:


      1. A01DWIO

        Disconnect the connector.

      2. Disconnect the 2 vacuum hoses.

      3. Remove the 2 bolts and electric vacuum regulating valve together with the bracket.

        Note

        Do not remove the electric vacuum regulating valve from the bracket.

  9. REMOVE NO. 2 INTAKE AIR CONNECTOR (w/ Intercooler)


    1. A01DZS6

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

  10. REMOVE INTAKE AIR CONNECTOR (w/ Intercooler)


    1. A01DW3T

      Remove the 3 bolts, intake air connector and 2 gaskets.

  11. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 1 EGR PIPE SUB-ASSEMBLY (w/ Intercooler)


    1. A01DX9H

      Remove the 2 nuts, electric EGR control valve with No. 1 EGR pipe and gasket.

  12. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY


    1. A01DWYQ

      w/ Intercooler:

      Remove the 2 bolts, No. 1 EGR pipe and gasket from the EGR valve adapter.

    2. A01DY8CE01
      Text in Illustration
      *1 Gasket

      w/o Intercooler:

      Remove the 2 bolts, 2 nuts, No. 1 EGR pipe and 2 gaskets.

  13. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01E03L

      w/ Intercooler:

      Remove the 2 bolts, electric EGR control valve and gasket from the EGR valve adapter.

    2. w/o Intercooler:


      1. Disconnect the EGR valve position sensor connector.

      2. Remove the electric EGR control valve and gasket.