EGR COOLER REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during EGR cooler assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure Necessary Procedure Effect/Inoperative Function when Necessary Procedure not Performed Link
Auxiliary battery terminal is disconnected/reconnected Memorize steering angle neutral point LKA/LDA system (for Mono camera type)
Lane control system (for Stereo camera type)
Parking support brake system*
Pre-collision system (for Stereo camera type)
Pre-collision system (for Mono camera type)
Adaptive high beam system

    Lighting system (EXT)

  • Cornering lights
Variable gear ratio steering system

Click here

Parking assist monitor system

Click here

Panoramic view monitor system

Click here

Initialize rear door sunshade system Rear door sunshade system

Click here

Initialize power trunk lid system Power trunk lid system

Click here


  • Replacement of EGR valve assembly

  • Gas leak from exhaust system is repaired

 Inspection After Repair

  • Poor idle, etc.

  • Engine start function, etc.
*: When performing learning using the GTS.
Click here Click here

CAUTION:


  • B004YIH

    This vehicle has contains high voltage circuits standardized with orange colored wiring and connectors, so follow the instructions in this manual to perform the procedures correctly.

  • If the correct procedures are not followed according to the instructions in this manual, there is a danger of electric shock from the high voltage circuits.

  • B004STG

    Be sure to wear insulating gloves when working on high voltage wiring or components.

  • If work is performed without wearing insulating gloves, there is a danger of electric shock.

  • B004UZ5

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

PROCEDURE


  1. PRECAUTION (for LHD)

    Note

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Click here

  2. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL (for LHD)

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Click here

  3. REMOVE SERVICE PLUG GRIP (for LHD)

    Click here

  4. REMOVE INVERTER COVER ASSEMBLY RH (for LHD)

    Click here

  5. REMOVE CONNECTOR COVER (for LHD)

    Click here

  6. CHECK TERMINAL VOLTAGE (for LHD)

    Click here

  7. TEMPORARILY INSTALL CONNECTOR COVER (for LHD)

    Click here

  8. REMOVE INVERTER TERMINAL COVER (for LHD)

    Click here

  9. DISCONNECT GENERATOR CABLE (for LHD)

    Click here

  10. DISCONNECT MOTOR CABLE (for LHD)

    Click here

  11. REMOVE INTAKE AIR SURGE TANK ASSEMBLY

    Click here

  12. REMOVE EGR VALVE ASSEMBLY

    Click here

  13. REMOVE INVERTER MOTOR CABLE BRACKET ASSEMBLY (for LHD)


    1. B004YGX

      Detach the 3 clamps and disconnect the generator cable and motor cable from the inverter motor cable bracket assembly.

    2. B004UL9

      Remove the 2 bolts and inverter motor cable bracket assembly from the inverter assembly.

  14. REMOVE FENDER APRON BRACE SUB-ASSEMBLY RH


    1. B004W51C01
      *A for LHD
      *B for RHD

      Detach the clamp and disconnect the hose from the fender apron brace sub-assembly RH.

    2. Remove the 2 bolts and fender apron brace sub-assembly RH from the body.

  15. REMOVE INLET HEATER WATER HOSE


    1. B004V7BC01
      *A for LHD
      *B for RHD

      Slide the 2 clamps and remove the inlet heater water hose from the No. 3 water by-pass pipe and heater pipe.

  16. REMOVE OUTLET HEATER WATER HOSE


    1. Slide the 2 clamps and remove the outlet heater water hose from the No. 2 water by-pass pipe and heater pipe.

  17. REMOVE NO. 1 EGR PIPE

    CAUTION:

    To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.


    1. B004RBTC02
      *A for 2WD
      *B for AWD

      Remove the 2 bolts, 2 nuts and No. 1 EGR pipe from the exhaust manifold assembly RH and EGR cooler assembly.

    2. Remove the 2 gaskets from the No. 1 EGR pipe and EGR cooler assembly.

  18. REMOVE NO. 4 WATER BY-PASS HOSE


    1. B004XUH

      Slide the clamp and remove the No. 4 water by-pass hose from the No. 3 water by-pass pipe.

  19. REMOVE NO. 3 WATER BY-PASS PIPE


    1. B004RUSC01

      for LHD:

      Remove the bolt and engine motor cable clamp bracket.

    2. Slide the clamp and remove the No. 3 water by-pass pipe from the EGR cooler assembly.

  20. DISCONNECT NO. 12 WATER BY-PASS HOSE


    1. B004TAG

      Slide the clamp and disconnect the No. 12 water by-pass hose from the EGR cooler assembly.

  21. REMOVE EGR COOLER ASSEMBLY

    CAUTION:

    To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.


    1. B004YT4

      Remove the bolt, nut and EGR cooler assembly from the cylinder head sub-assembly RH.