EGR VALVE REMOVAL

PROCEDURE

  1. DRAIN ENGINE COOLANT

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  2. REMOVE AIR CLEANER ASSEMBLY WITH ELEMENT

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  3. REMOVE PURGE VALVE (PURGE VSV)

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  4. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

    1. A423429

      Remove the 2 bolts, 2 nuts and No. 1 EGR pipe sub-assembly from the intake manifold and EGR valve assembly.

    2. Remove the 2 EGR pipe gaskets from the No. 1 EGR pipe sub-assembly and intake manifold.

  5. REMOVE EGR VALVE WITH COOLER ASSEMBLY

    1. A423430

      Disconnect the EGR valve assembly connector.

    2. A423431C01

      *1

      No. 2 Water By-pass Hose Assembly

      *2

      Water Hose Sub-assembly

      *3

      No. 4 Water By-pass Hose Assembly

      Slide the clip and disconnect the No. 2 water by-pass hose assembly from the EGR valve assembly.

    3. Slide the clip and disconnect the water hose sub-assembly from the EGR cooler assembly.

    4. Slide the clip and disconnect the No. 4 water by-pass hose assembly from the EGR cooler assembly.

    5. A423432

      Disengage the wire harness clamp and disconnect the engine wire.

    6. A423433

      Remove the 2 bolts, 2 nuts and EGR valve assembly with the EGR cooler assembly from the EGR valve bracket and cylinder head sub-assembly.

    7. Remove the EGR valve gasket from the EGR cooler assembly.

  6. REMOVE EGR VALVE ASSEMBLY

    1. A423436

      Slide the clip and disconnect the No. 3 water by-pass hose from the EGR valve assembly.

    2. A423434

      Remove the 2 nuts and EGR valve assembly from the EGR cooler assembly.

    3. Remove the No. 1 EGR cooler gasket from the EGR valve assembly.

    4. A423439

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the EGR valve assembly.

      Tip:

      If a stud bolt is deformed or the threads are damaged, replace it.