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

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Replacement Part

Gasket
 
Quantity: 2
 
Location of use: EGR cooler bypass valve

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

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
Switch the ignition off.
—
3
Wait for 30 s.
—
4
Switch the ignition ON (engine off).
—
5
Perform KOEO self-test procedure.
(See KOEO/KOER SELF TEST [PCM (SKYACTIV-D 2.2)].)
6
Perform KOER self-test procedure.
(See KOEO/KOER SELF TEST [PCM (SKYACTIV-D 2.2)].)


EGR Cooler Bypass Valve Removal/Installation

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

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

6.  Remove the nuts and set the turbocharger air outlet pipe component aside. (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.  Disconnect the compressor bypass solenoid valve connector. (See COMPRESSOR BYPASS SOLENOID VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

12.  Set the vacuum pipe bracket out of the way. (See COMPRESSOR BYPASS SOLENOID VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

13.  Remove in the order shown in the figure.

14.  Install in the reverse order of removal.

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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 Installation Note.)
4
EGR cooler bypass valve installation bolt No.1
(See EGR Cooler Bypass Valve Installation Bolt Installation Note.)
5
EGR cooler bypass valve installation bolt No.2
(See EGR Cooler Bypass Valve Installation Bolt Installation Note.)
6
EGR cooler bypass valve
(See Operation After Replacing EGR Cooler Bypass Valve)


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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