EGR COOLER REMOVAL

PROCEDURE


  1. DRAIN ENGINE COOLANT

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  2. REMOVE WINDSHIELD WIPER MOTOR AND LINK

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  3. REMOVE FRONT NO. 1 VENTILATOR SEAL


  4. REMOVE FRONT AIR SHUTTER SEAL RH


  5. REMOVE INNER COWL TOP TO COWL BRACE


  6. REMOVE OUTER COWL TOP PANEL


  7. REMOVE NO. 1 ENGINE COVER

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  8. DISCONNECT NO. 4 WATER BY-PASS HOSE


    1. B0047GP

      Slide the hose clip and disconnect the No. 4 water by-pass hose from the EGR cooler assembly.

  9. DISCONNECT VENTILATION HOSE ASSEMBLY


    1. B0046C8

      Slide the hose clip and disconnect the ventilation hose assembly from the PCV valve (ventilation valve sub-assembly).

    2. B004573

      Slide the hose clip and disconnect the ventilation hose assembly from the EGR cooler assembly.

  10. REMOVE NO. 3 WATER BY-PASS HOSE

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  11. DISCONNECT NO. 2 WATER BY-PASS HOSE

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  12. REMOVE EGR VALVE BRACKET (for LHD)

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  13. REMOVE EGR VALVE BRACKET (for RHD)

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  14. REMOVE EGR COOLER ASSEMBLY


    1. B0047G1

      Remove the 2 nuts.

    2. B0046EX

      Remove the bolt, 2 nuts and EGR cooler assembly together with the EGR valve assembly and EGR pipe assembly from the intake manifold and cylinder head sub-assembly.

    3. B00460D

      Remove the EGR inlet gasket from the intake manifold.

    4. B0046P7

      Remove the 2 nuts and EGR valve assembly from the EGR cooler assembly.

    5. B0047F5

      Remove the EGR valve gasket from the EGR valve assembly.

    6. B0047P9

      Remove the 2 bolts and EGR cooler assembly from the EGR pipe assembly.

    7. B00468U

      Remove the No. 1 EGR cooler gasket from the EGR cooler assembly.

    8. B0045XR

      Remove the EGR pipe gasket from the EGR pipe assembly.