EGR-1 Valve System Removal and Installation
Precautions: General safety (00)
Removal
1)Disconnect negative (–) cable at battery.
2)Remove engine cover. 
3)Drain coolant.
4)Remove battery and battery tray.
5)Remove air cleaner.
6)Remove DPF®.
7)Remove oil level gauge pipe (1).
8)Remove oil return pipe (2) and gasket.
9)Remove EGR cooler pipe (3) and gasket.
10)Disconnect the following electric connectors.
•ECT sensor (1)
•A/F sensor-1
•EGR-1 valve (2)
•A/F sensor-1
•EGR-1 valve (2)
11)Disconnect the following hoses and pipes.
•Radiator inlet hose (1)
•Degassing tank inlet hose (2)
•Heater inlet hose (3)
•Differential pressure sensor hose No.1 (4), No.2 (5), No.3 (6) and No.4 (7)
•Water hose (8)
•Hose connector (9)
•EGR pipe (10), gasket and O-ring
•Degassing tank inlet hose (2)
•Heater inlet hose (3)
•Differential pressure sensor hose No.1 (4), No.2 (5), No.3 (6) and No.4 (7)
•Water hose (8)
•Hose connector (9)
•EGR pipe (10), gasket and O-ring
12)Remove EGR-1 valve mounting (1) and gasket.
Installation
Reverse removal procedure noting the following points.
•Clean mating surfaces of EGR-1 valve mounting and cylinder head.
•Use new gaskets.
•Use new O-rings.
•Tighten each bolt and nut to specified torque.
EGR-1 valve mounting nut (b): 28 N·m (2.9 kgf-m, 21.0 lbf-ft)
•Refill cooling system with coolant.
•Check cooling system for leakage.
•Run engine and check for exhaust gas leakage.
•Use new gaskets.
•Use new O-rings.
•Tighten each bolt and nut to specified torque.
Tightening torque
EGR-1 valve mounting bolt (a): 28 N·m (2.9 kgf-m, 21.0 lbf-ft)EGR-1 valve mounting nut (b): 28 N·m (2.9 kgf-m, 21.0 lbf-ft)
•Check cooling system for leakage.
•Run engine and check for exhaust gas leakage.