EXHAUST COOLER REMOVAL

PROCEDURE


  1. DRAIN ENGINE COOLANT

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  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

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  3. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  4. REMOVE FAN AND GENERATOR V BELT

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  5. REMOVE GENERATOR ASSEMBLY


  6. DISCONNECT NO. 7 WATER BY-PASS HOSE


    1. B0046GS

      Slide the hose clip and disconnect the No. 7 water by-pass hose from the exhaust cooler assembly.

  7. REMOVE EXHAUST COOLER ASSEMBLY


    1. B004630

      Remove the 4 bolts, 3 nuts and exhaust cooler assembly from the cylinder head sub-assembly.

  8. REMOVE EXHAUST MANIFOLD TO HEAD GASKET


    1. B0046HJ

      Remove the exhaust manifold to head gasket from the cylinder head sub-assembly.

  9. REMOVE STRAIGHT SCREW PLUG

    Note

    If coolant leaks from a straight screw plug or the plug is corroded, replace it.


    1. Using a 10 mm hexagon socket wrench, remove the 4 straight screw plugs and 4 gaskets from the exhaust cooler assembly.

      B00481GC01
      *a RH Side *b Upper Side
      *c Lower Side - -

  10. REMOVE STUD BOLT

    Note

    If a stud bolt is deformed or its threads are damaged, replace it.


    1. B0046O9

      Using E6 and E8 "TORX" socket wrenches, remove the 9 stud bolts from the exhaust cooler assembly.