EGR COOLER (w/o EGR Cooler Bypass Valve) REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  2. DRAIN ENGINE COOLANT

    CAUTION:

    To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.


    1. A01KFNQE02
      Text in Illustration
      *1 Radiator Cap
      *2 Engine Drain Plug
      *3 Radiator Drain Plug

      Loosen the radiator drain plug (on the radiator).

    2. Remove the radiator cap.

    3. Loosen the engine drain plug (on the oil cooler cover), and drain the coolant.

    4. Drain the coolant from the reservoir tank.

    5. Tighten the engine drain plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  3. REMOVE FRONT SEAT ASSEMBLY LH (for Double Cab)


    1. Disconnect the connector.

    2. Remove the 4 bolts and front seat LH.

  4. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab)

    A01KG08

    1. Remove the 4 screws and front door scuff plate LH.

  5. REMOVE PARKING BRAKE HOLE COVER (for Double Cab)

    A01KHZT

    1. Remove the screw and parking brake hole cover.

  6. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Double Cab)

  7. REMOVE FRONT FLOOR PANEL BRACE (for Double Cab)

    A01KFZF

    1. Remove the 3 clips, then remove the floor panel brace with the shifting hole cover.

  8. REMOVE NO. 1 FRONT FLOOR MAT REAR (for Double Cab)

  9. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (for Double Cab)


    1. A01KHBQ

      Install the floor shift cable transmission control select with clip and washer.

    2. Install a new clip.

  10. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (for Double Cab)


    1. A01KEIB

      Install the floor shift cable transmission control shift with the nut and washer.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

    2. Install a new clip.

  11. REMOVE TRANSMISSION FLOOR SHIFT ASSEMBLY (for Double Cab)

    A01KGMH

    1. Remove the 4 bolts and transmission floor shift.

  12. SEPARATE PARKING BRAKE LEVER ASSEMBLY (for Double Cab)

    A01KH1U

    1. Disconnect the connector.

    2. Remove the 4 bolts, and separate the parking brake lever with parking brake cable.

  13. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY (for Double Cab)

    A01KEH0

    1. Remove the 7 bolts and engine service hole sub cover.

  14. REMOVE REAR DOOR SCUFF PLATE LH (for Double Cab)

    A01KF1Z

    1. Remove the 3 screws and rear door scuff plate.

  15. REMOVE REAR DOOR SCUFF PLATE RH (for Double Cab)

    A01KINS

    1. Remove the 3 screws and rear door scuff plate.

  16. REMOVE REAR FLOOR MAT (for Double Cab)

  17. REMOVE NO. 4 MAT SET PLATE (for Double Cab)

    A01KGPT

    1. Remove the 6 screws and mat set plate.

  18. REMOVE TRANSMISSION SERVICE HOLE COVER SUB-ASSEMBLY (for Double Cab)

    A01KIQM

    1. Remove the 12 bolts and service hole cover.

  19. REMOVE ENGINE SIDE COVER SUB-ASSEMBLY LH (for Double Cab)


    1. for Single Cab:

      Remove the 4 bolts and engine side cover LH.

    2. for Double Cab:

      Remove the 3 bolts and engine side cover LH.

  20. REMOVE EGR COOLER ASSEMBLY


    1. A01KENY

      Loosen the clamp and disconnect the oil return hose.

    2. Loosen the clamp and disconnect the No. 4 water by-pass hose.

    3. Loosen the clamp and disconnect the No. 2 water by-pass hose.

    4. A01KGQB

      Remove the 3 bolts, 2 nuts, EGR cooler assembly and 2 gaskets.