Inlet cover removal (RZ4E-TC)

1. Component views

Inlet cover (Except for Euro2 and Euro4 specifications)

Part name

  1. Gasket
  2. Inlet cover
  3. Relief valve control solenoid valve
  4. Nut
  5. Relief valve control solenoid valve bracket
  6. Nut
  7. Relief valve
  8. Gasket
  9. Gasket
  10. Bolt
  11. EGR pipe
  12. Gasket
  13. EGR duct
  14. Bolt
  15. Bolt
  16. Bolt
  17. Nut

Tightening torque

4: 25 N・m { 2.5 kgf・m / 18 lb・ft }

6: 25 N・m { 2.5 kgf・m / 18 lb・ft }

10: 25 N・m { 2.5 kgf・m / 18 lb・ft }

14: 25 N・m { 2.5 kgf・m / 18 lb・ft }

15: 25 N・m { 2.5 kgf・m / 18 lb・ft }

16: 25 N・m { 2.5 kgf・m / 18 lb・ft }

17: 25 N・m { 2.5 kgf・m / 18 lb・ft }

Inlet cover (Euro2 specifications)

Part name

  1. Gasket
  2. Inlet cover
  3. Nut
  4. Bolt
  5. EGR valve
  6. Gasket
  7. Gasket
  8. EGR pipe
  9. Gasket
  10. EGR duct
  11. Bolt
  12. Bolt
  13. Bolt
  14. Nut

Tightening torque

3: 25 N・m { 2.5 kgf・m / 18 lb・ft }

4: 25 N・m { 2.5 kgf・m / 18 lb・ft }

11: 25 N・m { 2.5 kgf・m / 18 lb・ft }

12: 25 N・m { 2.5 kgf・m / 18 lb・ft }

13: 25 N・m { 2.5 kgf・m / 18 lb・ft }

14: 25 N・m { 2.5 kgf・m / 18 lb・ft }

Inlet cover (Euro4 specifications)

Part name

  1. Gasket
  2. Inlet cover
  3. Nut
  4. Bolt
  5. EGR valve
  6. EGR valve gasket
  7. EGR valve gasket
  8. EGR cooler
  9. EGR cooler gasket
  10. EGR duct
  11. Bolt
  12. Bolt
  13. Bolt
  14. Nut
  15. Bolt

Tightening torque

3: 25 N・m { 2.5 kgf・m / 18 lb・ft }

4: 25 N・m { 2.5 kgf・m / 18 lb・ft }

11: 25 N・m { 2.5 kgf・m / 18 lb・ft }

12: 25 N・m { 2.5 kgf・m / 18 lb・ft }

13: 25 N・m { 2.5 kgf・m / 18 lb・ft }

14: 25 N・m { 2.5 kgf・m / 18 lb・ft }

15: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2. Generator removal

Refer to "1.Engine 1J.Electrical(RZ4E-TC) generator removal".

3. A/C compressor disconnect

1) Disconnect the pipe clip from the air duct bracket.

2) Disconnect the A/C compressor from the generator bracket.

Note

  • Secure with wire at an appropriate position as a set with the hoses.

4. Generator bracket removal

1) Remove the generator bracket from the cylinder block.

5. Intake air duct removal

1) Disconnect the connector from the boost pressure and CAC temperature sensor.

2) Remove the intake air duct from the intake throttle valve.

6. Intake throttle valve removal

1) Disconnect the connector from the intake throttle valve.

2) Remove the intake throttle valve and gasket from the inlet manifold.

Caution

  • Do not reuse the gasket.

Legend

  1. Intake throttle valve
  2. Gasket

7. Oil level gauge guide tube removal

1) Remove the oil level gauge from the oil level gauge guide tube.

2) Remove the oil level gauge guide tube from the crankcase.

8. Water pipe removal

1. Except for Euro4 specifications

1) Disconnect the vacuum hose from the vacuum pipe.

2) Remove the vacuum pipe from the air duct bracket.

Euro2 specifications

Legend

  1. Vacuum pipe
  2. Vacuum hose
  3. Bracket

Except for Euro2 specifications

Legend

  1. Vacuum hose
  2. Vacuum pipe
  3. Bracket
  4. Relief valve control solenoid valve
  5. Relief valve control solenoid valve bracket

3) Remove the water hose from the water pipe.

Manual transmission models

Automatic transmission models

4) Remove the water pipe from the air duct bracket.

5) Remove the pipe clip from the water pipe.

6) Remove the water pipe from the inlet cover.

Manual transmission models

Automatic transmission models

9. EGR cooler water hose disconnect

1. Euro4 specifications

1) Disconnect the EGR cooler water feed hose from the EGR cooler.

2) Disconnect the EGR cooler water return hose from the EGR cooler.

Manual transmission models

Legend

  1. EGR cooler water return hose
  2. EGR cooler water feed hose

Automatic transmission models

Legend

  1. EGR cooler water return hose
  2. EGR cooler water feed hose

3) Disconnect the EGR cooler water hose from EGR cooler water pipe A.

4) Remove EGR cooler water pipe A from the inlet cover.

Manual transmission models

Legend

  1. EGR cooler water pipe A
  2. EGR cooler water hose
  3. EGR cooler water pipe B

Automatic transmission models

Legend

  1. EGR cooler water pipe A
  2. EGR cooler water hose
  3. Water pipe

10. Relief valve removal

1. Except for Euro2 and Euro4 specifications

1) Remove the air duct bracket from the inlet cover.

2) Remove the harness bracket from the inlet cover.

3) Remove the following parts as a set from the cylinder head and inlet cover.

  • EGR pipe
  • EGR duct
  • Relief valve
  • Gasket
  • Relief valve control solenoid valve

Caution

  • Do not reuse the gasket.

Legend

  1. EGR duct
  2. EGR pipe
  3. Relief valve control solenoid valve bracket
  4. Relief valve control solenoid valve
  5. Relief valve
  6. Gasket

Caution

  • Do not reuse the gasket.
  • Seal to prevent foreign material from entering.

11. EGR removal

1. Euro2 specifications

1) Remove the air duct bracket from the inlet cover.

2) Remove the harness bracket from the inlet cover.

3) Remove the following parts as a set from the cylinder head and inlet cover.

  • EGR pipe
  • EGR valve
  • EGR duct
  • Gasket

Legend

  1. EGR duct
  2. EGR pipe
  3. EGR valve
  4. Gasket

4) Remove the following parts from the EGR pipe.

  • EGR valve
  • EGR duct
  • Gasket

Caution

  • Do not reuse the gasket.
  • Seal to prevent foreign material from entering.

2. Euro4 specifications

1) Disconnect the vacuum hose from the vacuum pipe.

2) Remove the vacuum pipe from the bracket.

Legend

  1. Vacuum pipe
  2. Vacuum hose
  3. Bracket

3) Remove the air duct bracket from the inlet cover.

4) Remove the harness bracket from the inlet cover.

5) Remove the following parts as a set from the cylinder head and inlet cover.

  • EGR cooler
  • EGR valve
  • EGR duct
  • Gasket

Caution

  • Do not reuse the gasket.

Legend

  1. EGR duct
  2. EGR cooler
  3. EGR valve
  4. Gasket

6) Remove the following parts from the EGR cooler.

  • EGR valve
  • EGR duct
  • Gasket

Caution

  • Do not reuse the gasket.
  • Seal to prevent foreign material from entering.

12. Inlet cover removal

1) Remove the inlet cover from the cylinder head.

Caution

  • Do not reuse the gasket.

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