EGR COOLER (w/ 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. A01KF9M

      Remove the clip.

    2. Remove the clip and washer, and separate the floor shift cable transmission control select.

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


    1. A01KECI

      Remove the clip.

    2. Remove the nut and washer, and separate the floor shift cable transmission control shift.

  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. DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY

    A01KGRN

    1. Remove the 2 bolts and disconnect the vane pump oil reservoir assembly.

  21. REMOVE NO. 4 AIR INJECTION SYSTEM HOSE

    A01KIOS

    1. Loosen the 2 clamps and remove the No. 4 air injection system hose.

  22. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    A01KF2W

    1. Disconnect the turbo pressure sensor connector and No. 1 vacuum switching valve assembly connector.

    2. A01KF62

      Remove the bolt and detach the wire harness clamp.

    3. A01KFNC

      Disconnect the intake air temperature sensor connector.

    4. A01KETQ

      Disconnect the 2 diesel throttle body assembly connectors.

    5. Remove the 2 bolts, 2 nuts, diesel throttle body assembly and gasket.

  23. REMOVE NO. 1 GAS FILTER

    A01KFFU

    1. Remove the bolt and gas filter.

  24. REMOVE ENGINE ROOM MAIN WIRE

    A01KF22

    1. Disconnect the EGR control valve connector.

    2. A01KFHM

      Detach the 2 wire harness clamps.

    3. A01KFL0

      Remove the bolt and detach the wire harness clamp.

    4. A01KGZF

      Disconnect the connector.

    5. Disconnect the vacuum hose.

  25. REMOVE MANIFOLD STAY

    A01KFKJ

    1. Detach the wire harness.

    2. Remove the 2 bolts and manifold stay.

  26. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    A01KFRG

    1. Disconnect the vacuum regulating valve connector.

    2. Disconnect the 2 vacuum hoses from the vacuum regulating valve.

    3. A01KEYL

      Remove the 2 bolts and remove the vacuum regulating valve with bracket.

    4. A01KHFQ

      Remove the 2 bolts and detach the No. 2 EGR pipe.

    5. Remove the bolt, 2 nuts, electric EGR control valve with intake air connector and 3 gaskets from the intake manifold.

    6. A01KFR1

      Disconnect the vacuum hose.

  27. DISCONNECT NO. 4 VACUUM TRANSMITTING HOSE ASSEMBLY

    A01KEQO

    1. Disconnect the No. 4 vacuum transmitting hoses from the EGR cooler assembly as shown in the illustration.

  28. DISCONNECT WATER BY-PASS HOSE

    A01KH8N

    1. Loosen the 2 clamps and disconnect the 2 water by-pass hoses as shown in the illustration.

  29. DISCONNECT NO. 3 WATER BY-PASS HOSE

    A01KFXT

    1. Loosen the clamp and disconnect the No. 3 water by-pass hose as shown in the illustration.

  30. REMOVE EGR COOLER ASSEMBLY

    A01KGXS

    1. Remove the 2 bolts, 2 nuts, EGR cooler assembly and gasket.

  31. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

    A01KEI1

    1. Remove the 2 nuts, No. 1 EGR pipe sub-assembly and gasket.