EGR COOLER REMOVAL


  1. TILT UP CAB

    CAUTION:


    • Make sure that the vehicle is on a level surface before tilting the cab up.

    • Make sure that all the doors are closed before tilting the cab up.

    • Make sure that nobody is inside or near the cab when tilting it up.

    • Be sure to have 2 people tilt the cab up when a heavy object such as a roof rack or cargo carrier is installed to the cab.

    • Be sure to remove anything set on top of the cab before tilting it up.

    • Make sure that the cab is securely locked in place after it is tilted up.

    • Make sure that there are no tools, cloths, etc. left in the engine room before tilting the cab back down.

    • Make sure that the cab is securely locked in place after tilting it back down.

  2. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator cap sub-assembly, radiator drain cock plug or engine drain plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. A01CGQLE01
      Text in Illustration
      *1 Radiator Cap Sub-assembly
      *2 Radiator Drain Cock Plug
      *3 Engine Drain Plug
      *4 Radiator Reservoir Assembly

      Loosen the radiator drain cock plug and engine drain plug.

    2. Remove the radiator cap sub-assembly, and then drain the coolant.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the local regulations.

    3. Tighten the radiator drain cock plug by hand.

    4. Tighten the engine drain plug.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

  3. REMOVE REAR ENGINE SIDE SHUTTER


    1. Remove the 4 bolts and rear engine side shutter from the rear cab mounting bracket sub-assembly.

  4. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  5. REMOVE EGR PIPE INSULATOR


    1. A01CHY1

      Remove the 2 bolts and EGR pipe insulator.

  6. REMOVE EGR COOLER SUB-ASSEMBLY


    1. A01CIX0

      Remove the 2 bolts.

    2. A01CHEE

      Slide the 2 clamps and disconnect the No. 5 radiator hose and water by-pass hose from the water by-pass pipe sub-assembly.

    3. Slide the 2 clamps and disconnect the No. 1 water by-pass hose and No. 2 water by-pass hose from the water by-pass pipe sub-assembly.

    4. Slide the clamp and disconnect the reserve tank hose from the water by-pass pipe sub-assembly.

    5. Remove the 4 bolts, EGR cooler sub-assembly and 2 gaskets.

  7. REMOVE EGR PIPE CONNECTOR


    1. A01CJ1H

      Remove the 3 nuts.

    2. Remove the EGR pipe connector and gasket.

  8. REMOVE NO. 1 EXHAUST PIPE HEAT INSULATOR SUB-ASSEMBLY


    1. A01CIXN

      Remove the 3 bolts and No. 1 exhaust pipe heat insulator sub-assembly from the EGR cooler sub-assembly.