GSIC - Global Service Information Center

# EGR VALVE > REMOVAL

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1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION:

  Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

1. Remove the 3 bolts, 2 nuts and cover.

3. REMOVE CHARGE AIR COOLER ASSEMBLY

1. Disconnect the diesel turbo IAT sensor connector.

1. Loosen the 2 hose clamps of the No. 1 air hose.

1. Loosen the 2 hose clamps of the No. 2 air hose.

1. Remove the 4 bolts and CAC.

1. Using a 22 mm deep socket wrench, remove the IAT sensor.

   HINT:
     Replace the IAT sensor if it is deformed, cracked or malfunctioning. It is not necessary to replace the IAT sensor each time the CAC is replaced.

1. Remove the 4 bolts, intake air connector and gasket.

4. REMOVE VACUUM SWITCHING VALVE BRACKET

1. Disconnect the 2 connectors.

1. Disconnect the vacuum hoses from the 3 locations.

1. Remove the 2 bolts and bracket.

5. REMOVE DIESEL THROTTLE BODY ASSEMBLY

1. Disconnect the 2 connectors.

1. Remove the 2 bolts, 2 nuts, throttle body and gasket.

6. REMOVE THROTTLE BODY BRACKET

1. Remove the 3 bolts and bracket.

7. REMOVE INTAKE AIR CONNECTOR

1. Remove the 2 nuts, bolt, air connector and bracket.

8. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

1. Remove the 2 bolts, 2 nuts, pipe and 2 gaskets.

9. REMOVE EGR VALVE ASSEMBLY

1. Remove the EGR valve and gasket.