EGR-2 Valve and EGR Cooler Removal and Installation
Precautions: General safety (00)
NOTE:
If EGR-2 valve is replaced, initialize EGR-2 valve data in ECM. For detail, refer to Description of ECM Registration:D16AA.
Removal
1)Disconnect negative (–) cable at battery.
2)Remove engine cover. 
3)Drain coolant.
4)Disconnect air cleaner outlet No.2 hose (1) from EGR-2 valve (2).
5)Disconnect connector (1) from EGR-2 valve.
6)Hoist vehicle and remove engine undercover.
7)Remove EGR lower pipe (2).
8)Remove turbocharger air outlet joint (3) and gasket.
9)Disconnect connector from EGT sensor-4 (4).
10)With A/C pipe connected, detach A/C compressor from its bracket and using a rope, hold A/C compressor in a place where no damage will be caused.
•Manual A/C model:
•Auto A/C model:
•Auto A/C model:
11)Loosen EGR cooler clamp (1).
12)Remove EGR-2 valve (2) from its bracket.
13)Remove EGR cooler (3) from its bracket.
14)Remove EGT sensor-4 (4) from EGR cooler, if necessary.
15)Remove EGR-2 valve bracket (1), if necessary.
16)Remove EGR cooler pipe bolts (1) and then remove EGR cooler bracket (2), if necessary.
Installation
1)Install EGR cooler bracket (1) to cylinder block, if removed.
2)Tighten EGR cooler pipe bolts to specified torque.
EGR cooler pipe bolt (b): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
Tightening torque
EGR cooler bracket bolt (a): 56 N·m (5.7 kgf-m, 41.5 lbf-ft)EGR cooler pipe bolt (b): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
3)Install EGR-2 valve bracket (1), if removed.
4)Install EGR cooler (1) with new O-ring to its bracket.
5)Install EGR-2 valve (1) to its bracket.
6)Tighten EGR cooler clamp (2).
7)Install EGT sensor-4 (3) to EGR cooler, if removed.
8)Install A/C compressor to its bracket.
•Manual A/C model:
•Auto A/C model:
•Auto A/C model:
9)Connect connector to EGT sensor-4.
10)Install turbocharger air outlet joint (4) with new gasket.
11)Install EGR lower pipe (5).
12)Connect connector to EGR-2 valve.
13)Connect air cleaner outlet No.2 hose (1) to EGR-2 valve.
14)Refill cooling system with coolant.
15)Install engine undercover.
16)Install engine cover.
17)Connect negative (–) cable at battery.
18)When replacing EGR-2 valve, initialize EGR-2 valve data in ECM.