EGR VALVE > REMOVAL |
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1. DRAIN ENGINE COOLANT (for Engine) |
- CAUTION:
- Do not remove the radiator cap sub-assembly or 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 hose with an inside diameter of 9 mm (0.354 in.) to the radiator drain cock as shown in the illustration.
Text in Illustration *1 Engine Under Cover LH *a Hose
Loosen the radiator drain cock plug.
Remove the radiator cap sub-assembly. Then drain the engine coolant.
Text in Illustration *1 Radiator Cap Sub-assembly *2 Radiator Drain Cock Plug - HINT:
- Collect the engine coolant in a container and dispose of it according to the regulations in your area.
Disconnect the hose from the radiator drain cock.
2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY |
Disengage the 3 grommets to remove the No. 1 engine cover sub-assembly.
- NOTICE:
- When removing the No. 1 engine cover sub-assembly, make sure to lift it upward. Pulling the No. 1 engine cover sub-assembly towards you may damage the No. 1 engine cover sub-assembly.
3. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE |
Slide the clip and disconnect the ventilation hose from the cylinder head cover sub-assembly.
Disengage the ventilation hose clamp.
Disconnect the mass air flow meter sub-assembly connector.
Disengage the wire harness clamp.
Disconnect the union to connector tube hose from the air cleaner hose sub-assembly.
Disengage the 2 air cleaner cap clamps and 2 guides.
Loosen the hose clamp and remove the air cleaner cap with air cleaner hose from the throttle body with motor assembly.
4. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY |
Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.
5. REMOVE AIR CLEANER CASE SUB-ASSEMBLY |
Disconnect the wire harness clamp.
Remove the 2 bolts and air cleaner case sub-assembly.
6. REMOVE FUEL PUMP PROTECTOR |
Remove the 2 bolts and fuel pump protector from the cylinder head cover sub-assembly.
7. REMOVE EGR PIPE CONNECTOR |
Remove the 4 bolts, nut and EGR pipe connector from the exhaust manifold converter sub-assembly (TWC: Front Catalyst), EGR cooler assembly and cylinder block sub-assembly.
Text in Illustration Bolt Nut
Remove the 2 EGR cooler gaskets from the EGR pipe connector.
8. REMOVE NO. 2 EGR PIPE |
Disengage the 2 wire harness clamps from the No. 2 EGR pipe.
Remove the 4 bolts and No. 2 EGR pipe from the EGR valve assembly and intake manifold.
Remove the No. 2 EGR pipe gasket from the EGR valve assembly.
Remove the EGR inlet gasket from the intake manifold.
9. DISCONNECT ENGINE WIRE |
Remove the 2 bolts and disconnect the 2 earth wires from the EGR valve bracket.
Text in Illustration *a Fuel Pump Sub-assembly Connector *b Ignition Coil Assembly Connector *c Camshaft Position Sensor Connector Bolt Nut
Remove the nut.
Disconnect the 2 camshaft position sensor connectors.
Disconnect the ignition coil assembly connector.
Disconnect the fuel pump sub-assembly connector.
Disengage the clamp.
Remove the bolt.
Disconnect the engine coolant temperature sensor connector.
10. REMOVE EGR VALVE WITH COOLER ASSEMBLY |
Disconnect the EGR valve assembly connector.
Remove the engine cover joint and separate the fuel hose bracket from the EGR valve bracket.
Remove the 4 bolts and 2 EGR valve brackets.
Disengage the water hose from the hose clamp.
Slide the clip and disconnect the water hose sub-assembly from the EGR cooler assembly.
Slide the clip and disconnect the No. 2 water by-pass hose from the EGR valve assembly.
Text in Illustration *1 No. 2 Water By-pass Hose *2 No. 3 Water By-pass Hose *3 No. 4 Water By-pass Hose
Slide the clip and disconnect the No. 3 water by-pass hose from the EGR cooler assembly.
Slide the clip and disconnect the No. 4 water by-pass hose from the EGR cooler assembly.
Remove the 2 nuts and EGR valve with cooler assembly from cylinder head sub-assembly.
Remove the No. 2 EGR pipe gasket from the EGR valve assembly.
11. REMOVE EGR VALVE ASSEMBLY |
Slide the clip and disconnect the No. 1 water by-pass hose from the EGR valve assembly.
Remove the 2 nuts and EGR valve assembly from the EGR cooler assembly.
Remove the EGR valve gasket from the EGR valve assembly.