Egr Valve -- Removal |
| 1. DRAIN ENGINE COOLANT |
- CAUTION:
- Do not remove the radiator reservoir cap sub-assembly, vent plug, radiator drain cock plug while the engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
Connect a vinyl tube with an inside diameter of 9 mm (0.354 in.) to the radiator drain cock as shown in the illustration.
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Loosen the radiator drain cock plug.
Text in Illustration *1 Radiator Reservoir Sub-assembly *2 Radiator Reservoir Cap Sub-assembly *3 Vent Plug *4 Cylinder Block Water Drain Cock Plug *5 Radiator Drain Cock Plug - -
Remove the radiator reservoir cap sub-assembly.
Using a wrench, remove the vent plug and drain the engine coolant from the radiator assembly.
- HINT:
- Collect the engine coolant in a container and dispose of it according to the local regulations.
Loosen the cylinder block water drain cock plug and drain the engine coolant from the engine.
Tighten the cylinder block water drain cock plug.
- Torque:
- 13 N*m{130 kgf*cm, 9 ft.*lbf}
Tighten the radiator drain cock plug by hand.
Remove the vinyl tube from the radiator drain cock.
| 2. REMOVE DIESEL THROTTLE BODY ASSEMBLY |
| 3. REMOVE WATER HOSE SUB-ASSEMBLY |
w/ Rear Air Conditioning System:
Slide the 2 clamps and disconnect the 2 water hoses from the water pipe.
Slide the 2 clamps and disconnect the 2 water hoses from the air conditioning unit assembly.
Slide the 2 clamps and disconnect the 2 water hoses from the No. 2 water by-pass pipe.
w/o Rear Air Conditioning System:
Slide the 2 clamps and disconnect the 2 water hoses from the air conditioning unit assembly.
Slide the 2 clamps and disconnect the 2 water hoses from the No. 2 water by-pass pipe.
| 4. REMOVE NO. 2 WATER BY-PASS PIPE |
Slide the clamp and disconnect the No. 13 water by-pass hose from the water outlet sub-assembly.
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Slide the clamp and disconnect the No. 15 water by-pass hose from the water by-pass pipe.
Slide the clamp and disconnect the No. 16 water by-pass hose from the No. 1 EGR cooler.
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.
| 5. REMOVE GAS FILTER |
Disconnect the 2 vacuum hoses from the turbo pressure sensor and intake manifold.
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Remove the gas filter from the gas filter bracket.
| 6. REMOVE DIESEL TURBO PRESSURE SENSOR |
Disconnect the connector from the turbo pressure sensor.
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Remove the bolt and turbo pressure sensor from the No. 3 water by-pass pipe sub-assembly.
| 7. REMOVE NO. 3 ENGINE COVER BRACKET |
Remove the 2 bolts and No. 3 engine cover bracket from the engine cover bracket and No. 2 engine cover bracket.
| 8. REMOVE NO. 2 ENGINE COVER BRACKET |
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.
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| 9. DISCONNECT UREA TANK FILLER PIPE ASSEMBLY (w/ Urea SCR System) |
Remove the 2 bolts and disconnect the urea tank filler pipe assembly from the body.
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| 10. DISCONNECT VANE PUMP OIL RESERVOIR SUB-ASSEMBLY |
Remove the 3 bolts and disconnect the vane pump oil reservoir sub-assembly from the body.
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| 11. DISCONNECT ENGINE WIRE |
Detach the 2 clamps and disconnect the 2 connectors from the turbocharger sub-assembly.
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Detach the clamp and disconnect the connector from the differential pressure sensor.
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Disconnect the 3 connectors from the exhaust gas temperature sensors.
Disconnect the connector from the exhaust fuel addition injector assembly.
Disconnect the camshaft position sensor.
Disconnect the 4 connectors from the 4 injector assemblies.
Disconnect the electric EGR control valve assembly.
Disconnect the connector from the glow plug connector.
Disconnect the connector from the sensor wire of common rail assembly.
Detach the clamp and remove the bolt.
Detach the clamp and disconnect the 2 connectors from the vane pump assembly.
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Detach the clamp and remove the bolt.
Disconnect the 2 connectors from the 2 vacuum control valve sets.
| 12. REMOVE EGR VALVE BRACKET |
Remove the bolt, nut and EGR valve bracket from the electric EGR control valve assembly and intake manifold.
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| 13. REMOVE NO. 2 EGR PIPE |
Remove the bolt, 4 nuts and No. 2 EGR pipe from the electric EGR control valve assembly and intake manifold.
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Remove the 2 gaskets.
| 14. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY |
Detach the clamp and disconnect the connector from the common rail assembly.
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Slide the clamp and disconnect the No. 9 water by-pass hose from the electric EGR control valve assembly.
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Remove the 2 bolts and electric EGR control valve assembly.
Remove the gasket.
| 15. REMOVE NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY |
Disconnect the No. 4 fuel hose from the No. 3 water by-pass pipe sub-assembly.
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Slide the clamp and disconnect the No. 8 water by-pass hose from the No. 3 water by-pass pipe sub-assembly.
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| 16. DISCONNECT NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY |
Slide the clamp and disconnect the No. 7 water by-pass hose from the No. 1 EGR cooler.
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Slide the clamp and disconnect the water hose from the No. 2 EGR valve assembly.
Remove the 2 bolts and disconnect the No. 4 water by-pass pipe sub-assembly from the intake manifold.
| 17. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY |
Remove the bolt and disconnect the No. 1 EGR pipe sub-assembly from the vacuum transmitting pipe sub-assembly.
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Remove the 4 nuts and the No. 1 EGR pipe sub-assembly from the exhaust manifold and EGR valve adapter.
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Remove the 2 gaskets.
Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold.
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| 18. REMOVE VACUUM CONTROL VALVE SET |
Remove the bolt and disconnect the engine wire bracket.
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Disconnect the connector from the vacuum control valve set.
Disconnect the 2 vacuum hoses from the No. 2 vacuum transmitting pipe sub-assembly and No. 2 EGR valve assembly.
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Remove the 2 bolts and vacuum control valve set from the intake manifold.
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| 19. REMOVE NO. 1 EGR COOLER WITH NO. 2 EGR VALVE ASSEMBLY |
Remove the 4 bolts and No. 1 EGR cooler with No. 2 EGR valve assembly from the intake manifold.
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| 20. REMOVE EGR VALVE ADAPTER |
Remove the 2 bolts and EGR valve adapter from the No. 2 EGR valve assembly.
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Remove the gasket.
| 21. REMOVE NO. 2 EGR VALVE ASSEMBLY |
Remove the 4 bolts and No. 2 EGR valve assembly from the No. 1 EGR cooler.
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Remove the gasket.
Using an E8 "TORX" socket wrench, remove the 4 stud bolts from the No. 2 EGR valve assembly.
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