EGR VALVE REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the EGR valve removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedures Effects/Inoperative when not Performed Link
Replacement of diesel throttle body assembly Perform initialization -
Replacement of electric EGR control valve assembly Perform initialization -

CAUTION:

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

B0068EY

PROCEDURE


  1. DRAIN ENGINE COOLANT

    Click here

  2. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  3. REMOVE NO. 2 WATER BY-PASS PIPE

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.


    1. w/ Heater:


      1. B0027X2

        w/ DPF:

        Slide the clamp and disconnect the No. 18 water by-pass hose from the EGR pipe with cooler sub-assembly.

      2. B0024LLC01
        *1 Water Hose Sub-assembly
        *2 No. 13 Water By-pass Hose
        *3 No. 15 Water By-pass Hose
        *4 Heater Hose
        *5 No. 16 Water By-pass Hose

        w/ Viscous Heater:

        Slide the clamp and disconnect the No. 2 water by-pass pipe from the water hose sub-assembly.

      3. w/o Viscous Heater:

        Slide the clamp and disconnect the No. 2 water by-pass pipe from the No. 13 water by-pass hose.

      4. Slide the clamp and disconnect the No. 15 water by-pass hose from the water by-pass pipe.

      5. Slide the 2 clamps and disconnect the 2 heater hoses from the No. 2 water by-pass pipe.

      6. Slide the clamp and disconnect the No. 16 water by-pass hose from the No. 1 EGR cooler.

      7. Remove the 4 bolts and No. 2 water by-pass pipe from the cylinder head cover sub-assembly, No. 3 water by-pass pipe sub-assembly and No. 2 engine cover bracket.

    2. B0027JFC01
      *1 No. 15 Water By-pass Hose
      *2 No. 16 Water By-pass Hose

      w/o Heater:


      1. Slide the clamp and disconnect the No. 15 water by-pass hose from the water by-pass pipe.

      2. Slide the clamp and disconnect the No. 16 water by-pass hose from the No. 1 EGR cooler.

      3. Remove the 3 bolts and No. 2 water by-pass pipe from the cylinder head cover sub-assembly, No. 3 water by-pass pipe sub-assembly and No. 2 engine cover bracket.

  4. REMOVE GAS FILTER


    1. B0024JX

      Disconnect the 2 vacuum hoses from the turbo pressure sensor and intake manifold.

    2. Remove the gas filter from the gas filter bracket.

  5. REMOVE TURBO PRESSURE SENSOR


    1. B002518

      Disconnect the connector from the turbo pressure sensor.

    2. Remove the bolt and turbo pressure sensor from the No. 3 water by-pass pipe sub-assembly.

  6. REMOVE NO. 2 HOSE TO HOSE TUBE


    1. B002482

      Slide the clamp to disconnect the union to connector tube hose from the No. 1 hose to hose tube.

    2. Slide the clamp to disconnect the union to check valve hose from the vacuum pump assembly.

    3. Remove the 2 bolts and No. 2 hose to hose tube from the cylinder head cover sub-assembly and hose bracket.

  7. REMOVE NO. 2 ENGINE COVER BRACKET


    1. B0027EB

      Remove the 2 bolts and No. 2 engine cover bracket from the No. 3 water by-pass pipe sub-assembly and No. 2 EGR valve assembly.

  8. DISCONNECT FUEL FILTER ASSEMBLY


    1. B0027DON01

      Disconnect the clamp and slide the lead wire as shown in the illustration to remove it.

    2. B0028V8

      Disconnect the fuel filter assembly from the fuel filter support.

  9. DISCONNECT UREA TANK FILLER PIPE ASSEMBLY (w/ Urea SCR System)


    1. B0027UF

      Detach the claw and disconnect the urea tank filler pipe assembly from the No. 1 urea tank filler pipe support.

  10. REMOVE NO. 1 UREA TANK FILLER PIPE SUPPORT (w/ Urea SCR System)


    1. B00280W

      Remove the 2 bolts and No. 1 urea tank filler pipe support from the body.

  11. DISCONNECT ENGINE WIRE


    1. B0024YW

      Detach the 2 clamps and disconnect the 2 connectors from the turbocharger sub-assembly.

    2. B0025V8

      w/ DPF:


      1. Disconnect the connector from the differential pressure sensor.

      2. Disconnect the 3 connectors from the 3 exhaust gas temperature sensors

      3. Disconnect the connector from the exhaust fuel addition injector assembly.

      4. Disconnect the connector from the camshaft position sensor.

      5. Disconnect the 4 connectors from the 4 injector assemblies.

      6. Disconnect the connector from the electric EGR control valve assembly.

      7. Disconnect the connector from the glow plug connector.

      8. Disconnect the connector from the sensor wire of common rail assembly.

      9. Detach the 2 clamps and remove the bolt.

    3. B002826

      w/o DPF:


      1. Disconnect the connector from the camshaft position sensor.

      2. Disconnect the 4 connectors from the 4 injector assemblies.

      3. Disconnect the connector from the electric EGR control valve assembly.

      4. Disconnect the connector from the glow plug connector.

      5. Disconnect the connector from the sensor wire of common rail assembly.

      6. Detach the clamp and remove the bolt.

    4. B002715

      Detach the clamp and disconnect the connector from the power steering oil pressure switch.

    5. Detach the clamp and remove the bolt.

    6. Disconnect the connector from the vacuum control valve set.

  12. REMOVE EGR VALVE BRACKET

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.


    1. B0028CU

      Remove the bolt, nut and EGR valve bracket from the electric EGR control valve assembly and intake manifold.

  13. REMOVE NO. 2 EGR PIPE

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.


    1. B0028YZ

      Remove the bolt, 4 nuts and No. 2 EGR pipe from the electric EGR control valve assembly and intake manifold.

    2. Remove the 2 gaskets.

  14. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.


    1. B0026O8

      Detach the clamp and disconnect the connector from the common rail assembly.

    2. B0026KT

      Slide the clamp and disconnect the No. 9 water by-pass hose from the electric EGR control valve assembly.

    3. Remove the 2 bolts and electric EGR control valve assembly.

    4. Remove the gasket.

  15. REMOVE NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.


    1. B00294Q

      Disconnect the No. 4 fuel hose from the No. 3 water by-pass pipe sub-assembly.

    2. B0026XM

      Slide the clamp and disconnect the No. 8 water by-pass hose from the No. 3 water by-pass pipe sub-assembly.

    3. Remove the 2 bolts and No. 3 water by-pass pipe sub-assembly from the No. 1 EGR cooler.

  16. DISCONNECT NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.


    1. B00251H

      w/ DPF:

      Slide the clamp and disconnect the No. 17 water by-pass hose from the No. 1 EGR pipe sub-assembly.

    2. B00249UC01
      *A w/ DPF
      *B w/o DPF

      Slide the clamp and disconnect the No. 7 water by-pass hose from the No. 1 EGR cooler.

    3. Slide the clamp and disconnect the water hose from the No. 2 EGR valve assembly.

    4. Remove the 2 bolts and disconnect the No. 4 water by-pass pipe sub-assembly from the intake manifold.

  17. REMOVE EGR PIPE WITH COOLER SUB-ASSEMBLY (w/ DPF)

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.


    1. B0026OH

      Remove the bolt and disconnect the EGR pipe with cooler sub-assembly from the vacuum transmitting pipe sub-assembly.

    2. B0025PR

      Remove the 4 nuts and the EGR pipe with cooler sub-assembly from the exhaust manifold and EGR valve adapter.

    3. Remove the 2 gaskets.

    4. B00262M

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold.

  18. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY (w/o DPF)

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.


    1. B00284H

      Remove the bolt and disconnect the No. 1 EGR pipe sub-assembly from the vacuum transmitting pipe sub-assembly.

    2. B0027HV

      Remove the 4 nuts and the No. 1 EGR pipe sub-assembly from the exhaust manifold and EGR valve adapter.

    3. Remove the 2 gaskets.

    4. B00262M

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold.

  19. REMOVE VACUUM CONTROL VALVE SET


    1. B0024HG

      Remove the bolt and engine wire bracket.

    2. B00290I

      Disconnect the 2 vacuum hoses from the No. 2 vacuum transmitting pipe sub-assembly and No. 2 EGR valve assembly.

    3. B00250B

      Remove the 2 bolts and vacuum control valve set from the intake manifold.

  20. REMOVE NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.


    1. B0024UD

      Remove the 4 bolts and No. 1 EGR cooler and No. 2 EGR valve assembly from the intake manifold.

  21. REMOVE EGR VALVE ADAPTER


    1. B00270V

      Remove the 2 bolts and EGR valve adapter from the No. 2 EGR valve assembly.

    2. Remove the gasket.

  22. REMOVE NO. 2 EGR VALVE ASSEMBLY


    1. B0026NP

      Remove the 4 bolts and No. 2 EGR valve assembly from the No. 1 EGR cooler.

    2. Remove the gasket.

    3. B0028GB

      Using an E8 "TORX" socket wrench, remove the 4 stud bolts from the No. 2 EGR valve assembly.