EGR COOLER (w/ DPF) REMOVAL

Note


  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.


  1. 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 }

  2. 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.

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

    A01KF1Z

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

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

    A01KINS

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

  5. REMOVE REAR FLOOR MAT (for Double Cab)

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

  7. REMOVE INJECTOR DRIVER

    Click here

  8. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  9. DISCONNECT NO. 4 WATER BY-PASS HOSE


    1. A01KFS8

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

  10. DISCONNECT NO. 7 WATER BY-PASS HOSE


    1. Loosen the hose clamp and disconnect the No. 7 water by-pass hose.

  11. REMOVE WATER BY-PASS HOSE ASSEMBLY


    1. A01KFUY

      Loosen the 2 hose clamps and remove the water by-pass hose assembly.

  12. REMOVE NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01KHNH

      Loosen the hose clamp and disconnect the No. 7 water by-pass hose.

    2. Remove the bolt.

    3. Loosen the hose clamp and remove the No. 4 water by-pass pipe sub-assembly from the No. 2 water by-pass hose.

  13. SEPARATE EMISSION CONTROL VALVE WIRE


    1. A01KFVH

      Disconnect the emission control valve wire connector.

    2. Disengage the wire harness clamp and separate the emission control valve wire.

  14. REMOVE EGR VALVE BRACKET


    1. A01KHHH

      Remove the 2 bolts and EGR valve bracket.

  15. REMOVE EGR VALVE ADAPTER


    1. A01KERE

      Remove the 2 nuts and 3 bolts, remove the EGR valve adapter.

  16. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01KGR3

      Remove the electric EGR control valve assembly.

    2. Disconnect the emission control valve wire.

  17. REMOVE NO. 3 VACUUM SWITCHING VALVE ASSEMBLY

    A01KF08

    1. Disconnect the No. 3 vacuum switching valve assembly connector.

    2. Disconnect the 2 vacuum hoses.

    3. Remove the bolt and No. 3 vacuum switching valve assembly.

  18. REMOVE NO. 3 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. A01KGPX

      Disconnect the 2 vacuum hoses from the No. 3 vacuum transmitting pipe sub-assembly.

    2. Remove the 2 bolts and No. 3 vacuum transmitting pipe sub-assembly.

  19. SEPARATE ENGINE WIRE

    A01KETD

    1. Remove the bolt and separate the wire harness.

    2. Disengage the wire harness clamp.

    3. Disconnect the manifold absolute pressure sensor connector.

    4. Disconnect the intake air temperature sensor connector.

  20. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01KHJY

      Detach the clamp and remove the bolt and engine oil level dipstick guide.

    2. Remove the O-ring from the engine oil level dipstick guide.

  21. REMOVE NO. 1 GAS FILTER


    1. A01KG1Z

      Disconnect the 2 vacuum hose and No. 1 gas filter from the gas filter bracket.

  22. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. Remove the 2 bolts and manifold absolute pressure sensor.

  23. REMOVE GAS FILTER BRACKET


    1. A01KF13

      Remove the bolt and gas filter bracket.

  24. REMOVE MANIFOLD STAY


    1. A01KF8T

      Remove the 2 bolts and manifold stay.

  25. DISCONNECT NO. 3 WATER BY-PASS HOSE


    1. A01KF7C

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

  26. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A01KFQN

      Using a 17 mm union nut wrench, loosen the union nut.

    2. Remove the 2 bolts and inlet fuel pipe sub-assembly.

  27. REMOVE EGR VALVE ADAPTER

    A01KERE

    1. Remove the 2 nuts and 3 bolts, remove the EGR valve adapter.

  28. REMOVE INTAKE AIR CONNECTOR ASSEMBLY


    1. A01KFDU

      Remove the 2 bolts, 2 nuts and intake air connector assembly.

    2. Remove the gasket.

  29. REMOVE INTAKE AIR TEMPERATURE SENSOR


    1. Disconnect the intake air temperature sensor connector.

    2. A01KGGG

      Using a 22 mm ball joint lock nut wrench, remove the intake air temperature sensor and gasket.

      Tech Tips

      Replace the intake air temperature sensor if it is deformed, cracked or malfunctioning.

  30. REMOVE INTAKE AIR CONNECTOR


    1. A01KG0S

      Remove the 3 bolts and intake air connector.

    2. Remove the gasket.

  31. REMOVE EGR COOLER ASSEMBLY WITH NO. 2 EGR VALVE ASSEMBLY


    1. Remove the 2 nuts, 3 bolts and EGR cooler assembly with No. 2 EGR valve assembly.

      A01KGSX