EGR COOLER BYPASS VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

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Note
•  If the EGR cooler bypass valve is replaced, perform the “Operation After Replacing EGR Cooler Bypass Valve”.

Operation After Replacing EGR Cooler Bypass Valve

1.  If the EGR cooler bypass valve is replaced, perform the following procedure.

STEP

ACTION

PAGE/CONDITION
1
Perform EGR cooler bypass valve initialization procedure.
(See EGR COOLER BYPASS VALVE INITIALIZATION [SKYACTIV-D 2.2].)
2
Wait for 20 s.
—
3
Perform KOEO self-test procedure.
(See KOEO/KOER SELF TEST [SKYACTIV-D 2.2].)
4
Perform KOER self-test procedure.
(See KOEO/KOER SELF TEST [SKYACTIV-D 2.2].)


EGR Cooler Bypass Valve Removal/Installation

1.  Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 2.2].)

2.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

3.  Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

4.  Remove the battery and the battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

5.  Remove the following parts as a single unit: (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Air hose
•  Air inlet pipe
•  Breather hose
•  Turbocharger air inlet hose
•  Blow-by heater

6.  Set the turbocharger air outlet pipe component aside as a single unit as shown in the figure. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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7.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 2.2].)

8.  Set the water pipe component aside as shown in the figure.

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9.  Remove the EGR pipe (EGR valve side). (See EGR PIPE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

10.  Set the EGR cooler out of the way. (See EGR COOLER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

11.  Remove in the order shown in the figure.

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1
EGR cooler bypass valve connector
2
Water hose No.1
(See Water Hose No.1 Installation Note.)
3
Water hose No.2
(See Water hose No.2 Removal Note.)
(See Water Hose No.2 Installation Note.)
4
Wiring harness bracket
5
EGR cooler bypass valve installation bolt No.1
(See EGR Cooler Bypass Valve Installation Bolt Installation Note.)
6
EGR cooler bypass valve installation bolt No.2
(See EGR Cooler Bypass Valve Installation Bolt Installation Note.)
7
EGR cooler bypass valve
(See Operation After Replacing EGR Cooler Bypass Valve)

12.  Install in the reverse order of removal.


Water hose No.2 Removal Note

1.  Remove the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

2.  Remove the water hose No.2.


EGR Cooler Bypass Valve Installation Bolt Installation Note

1.  Temporarily tighten the bolt until the flanged of the retaining bolt No.1 and No.2 of the EGR pipe (of the EGR cooler bypass valve) are completely seated.

2.  Tighten the EGR cooler bypass valve installation bolt No.2.

Tightening torque
20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf}

3.  Tighten the EGR cooler bypass valve installation bolt No.1.

Tightening torque
20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf}


Water Hose No.2 Installation Note

1.  Install water hose No.2 as shown in the figure.

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Water Hose No.1 Installation Note

1.  Install water hose No.1 as shown in the figure.

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