EGR VALVE > REMOVAL

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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.

1. 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

2. Loosen the radiator drain cock plug.
   

3. 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.

4. Disconnect the hose from the radiator drain cock.
   

1. 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.

1. Slide the clip and disconnect the ventilation hose from the cylinder head cover sub-assembly.
   

2. Disengage the ventilation hose clamp.
   

3. Disconnect the mass air flow meter sub-assembly connector.
   

4. Disengage the wire harness clamp.
   

5. Disconnect the union to connector tube hose from the air cleaner hose sub-assembly.
   

6. Disengage the 2 air cleaner cap clamps and 2 guides.
   

7. Loosen the hose clamp and remove the air cleaner cap with air cleaner hose from the throttle body with motor assembly.
   

1. Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.
   

1. Disconnect the wire harness clamp.
   

2. Remove the 2 bolts and air cleaner case sub-assembly.
   

1. Remove the 2 bolts and fuel pump protector from the cylinder head cover sub-assembly.
   

1. 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

2. Remove the 2 EGR cooler gaskets from the EGR pipe connector.
   

1. Disengage the 2 wire harness clamps from the No. 2 EGR pipe.
   

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

3. Remove the No. 2 EGR pipe gasket from the EGR valve assembly.
   

4. Remove the EGR inlet gasket from the intake manifold.
   

1. 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

2. Remove the nut.
   

3. Disconnect the 2 camshaft position sensor connectors.
   

4. Disconnect the ignition coil assembly connector.
   

5. Disconnect the fuel pump sub-assembly connector.
   

6. Disengage the clamp.
   

7. Remove the bolt.
   

8. Disconnect the engine coolant temperature sensor connector.
   

1. Disconnect the EGR valve assembly connector.
   

2. Remove the engine cover joint and separate the fuel hose bracket from the EGR valve bracket.
   

3. Remove the 4 bolts and 2 EGR valve brackets.
   

4. Disengage the water hose from the hose clamp.
   

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

6. 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

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

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

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

10. Remove the No. 2 EGR pipe gasket from the EGR valve assembly.
    

1. Slide the clip and disconnect the No. 1 water by-pass hose from the EGR valve assembly.
   

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

3. Remove the EGR valve gasket from the EGR valve assembly.