REMOVAL AND INSTALLATION

			Removal steps
		1.	Harness bracket
		2.	Alternator bracket upper
		3.	EGR temperature sensor
		4.	Vacuum hose
		5.	Solenoid valve
		6.	Vacuum hose
		7.	Vacuum hose
		8.	E-VRV assembly
		9.	Throttle body
	>>F<<	10.	Throttle body gasket
	>>E<<	11.	EGR pipe B
	>>E<<	12.	EGR pipe gasket
	>>E<<	13.	EGR pipe gasket
	>>D<<	14.	Inlet manifold
	>>C<<	15.	Inlet manifold gasket
		16.	Water hose B
		17.	Water hose A
	>>B<<	18.	EGR pipe A
	>>B<<	19.	EGR pipe gasket
	>>B<<	20.	EGR pipe gasket
<<B>>	>>B<<	21.	EGR valve
	>>B<<	22.	EGR valve gasket
<<A>>	>>A<<	23.	Glow plug

REMOVAL SERVICE POINTS

<<A>> GLOW PLUG REMOVAL

caution

When removing the glow plug, do not bring the end of the glow plug in contact with the cylinder head hole.
Do not use the glow plug that has fallen down.

<<B>> EGR VALVE ASSEMBLY REMOVAL

note

Use the recommended tool f/head & o/end combination wrench (MB992699) to remove the EGR valve mounting bolt shown in the figure.

INSTALLATION SERVICE POINTS

>>A<< GLOW PLUG INSTALLATION

caution

Do not use electric tools to install the glow plug. If using electric tools, the glow plug can be damaged.
When installing the glow plug, do not bring the end of the glow plug in contact with the cylinder head hole.
Do not use the glow plug that has fallen down.

1.Insert the glow plug into the cylinder head. Rotate them 2 or 3 times by hand to temporarily install them. Use the wrench and temporarily tighten them.

2.To the specified torque of 18 ± 2 N·m, tighten the glow plug that is temporarily tightened.

>>B<< EGR PIPE A / EGR PIPE GASKET / EGR VALVE / EGR VALVE GASKET INSTALLATION

1.Temporarily install the EGR pipe "A" and the EGR pipe gasket to the EGR valve. Put the EGR pipe gasket tab to the position shown in the illustration.

2.Put the EGR valve gasket tab to the position shown in the illustration.
3.Install the temporarily tightened EGR pipe A and the EGR valve to the cylinder head and the EGR cooler. Check that there is no clearance among each component. Temporarily tighten the bolts, 1, 4 and 6, as shown in the illustration.
Temporary tightening torque: 1.3 ± 0.7 N·m
4.To the specified torque, tighten each bolt in the order shown in the illustration.
Specified torque: 20 ± 2 N·m

>>C<< INLET MANIFOLD GASKET INSTALLATION

Put the inlet manifold gasket tab to the position shown in the illustration. Install the inlet manifold gasket to the cylinder head.

>>D<< INLET MANIFOLD INSTALLATION

1.Check the vacuum outlet port for clogging, and clean it if necessary.

2.Temporarily install the inlet manifold to the cylinder head.

3.In accordance with the order shown in the illustration, tighten the inlet manifold bolts and nuts to the specified torque of 20 ± 2 N·m.

>>E<< EGR PIPE B / EGR PIPE GASKET INSTALLATION

1.Put the EGR pipe gasket tab to the position shown in the illustration.
2.Install the temporarily tightened EGR pipe B to the EGR valve and the inlet manifold. Check that there is no clearance among each component.
Temporary tightening torque: 1.3 ± 0.7 N·m
3.Install the tightened EGR pipe B to the specified torque.
Specified torque: 20 ± 2 N·m

>>F<< THROTTLE BODY GASKET INSTALLATION

Put the throttle body gasket tab to the position shown in the illustration to install the inlet manifold.