EGR COOLER (w/ DPF) REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

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

  • After removing the injection pipes, clean them with a brush and compressed air.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  2. REMOVE FRONT DOOR SCUFF PLATE RH

  3. REMOVE FRONT SEAT ASSEMBLY RH

  4. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY

  5. DRAIN ENGINE COOLANT

    A01BDM5E01

    CAUTION:

    To avoid the danger of being burned, do not remove the reservoir 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. Loosen the radiator drain plug.

    2. Remove the reservoir cap.

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

    4. Tighten the radiator drain plug.

    5. Tighten the cylinder block drain plug (on the engine oil cooler cover).

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

  6. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  7. DISCONNECT WATER BY-PASS HOSE


    1. A01BEY4

      Disconnect the 2 water by-pass hoses.

  8. REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY (for Automatic Transmission)


    1. A01BEJN

      Remove the 2 bolts and transmission oil filler tube.

    2. Remove the O-ring from the transmission oil filler tube.

  9. REMOVE WATER BY-PASS HOSE ASSEMBLY


    1. A01BHI9

      Remove the water by-pass hose.

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


    1. A01BD2P

      Remove the No. 7 water by-pass hose from the No. 4 water by-pass pipe.

    2. Remove the bolt and No. 4 water by-pass pipe from the No. 2 water by-pass hose.

  11. DISCONNECT WIRING HARNESS CONNECTOR


    1. A01BAOU

      Disconnect the wiring harness connector and detach the clamp.

  12. REMOVE EGR VALVE BRACKET


    1. A01BEZ1

      Remove the 2 bolts and EGR valve bracket.

  13. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY


    1. A01BA7M

      Remove the 3 bolts, 2 nuts and No. 2 EGR pipe.

    2. Remove the 2 gaskets.

  14. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01BAQ2

      Remove the 2 stud bolts, electric EGR control valve.

    2. Remove the wiring harness connector from the electric EGR control valve.

  15. REMOVE VACUUM CONTROL VALVE SET


    1. A01BBW7

      Disconnect the vacuum control valve connector and 2 vacuum hoses.

    2. Remove the bolt and vacuum control valve set.

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


    1. A01BFXP

      Disconnect the 2 vacuum hoses.

    2. Remove the 2 bolts and No. 3 vacuum transmitting pipe.

  17. DISCONNECT ENGINE ROOM MAIN WIRE


    1. A01BF5M

      Detach the clamp and disconnect the 3 engine room main wire connectors.

  18. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01BESH

      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.

  19. REMOVE NO. 1 GAS FILTER


    1. A01BH8Y

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

  20. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR


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

  21. REMOVE GAS FILTER BRACKET


    1. A01BFRO

      Remove the bolt and gas filter bracket.

  22. REMOVE MANIFOLD STAY


    1. A01BAS6

      Remove the 2 bolts and manifold stay.

  23. DISCONNECT NO. 3 WATER BY-PASS HOSE


    1. A01BALU

      Disconnect the No. 3 water by-pass hose.

  24. REMOVE INTAKE AIR CONNECTOR ASSEMBLY


    1. A01BA7Q

      Remove the 2 bolts and 2 nuts.

    2. A01BGB5

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts, intake air connector and gasket.

  25. REMOVE INTAKE AIR TEMPERATURE SENSOR


    1. Disconnect the intake air temperature sensor connector.

    2. A01BEWGE01

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

    3. Remove the gasket from the intake air temperature sensor.

  26. REMOVE INTAKE AIR CONNECTOR


    1. A01BERX

      Remove the 3 bolts, intake air connector and gasket.

  27. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Note

    If a No. 1 injection pipe clamp is removed from the fuel inlet pipe, replace the No. 1 injection pipe clamp with a new one.


    1. A01BFWK

      Remove the 2 bolts and 2 No. 1 injection pipe clamps.

    2. Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.

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


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

      A01BDRG

    2. Remove the gasket from the cylinder head.

  29. REMOVE NO. 2 EGR VALVE ASSEMBLY


    1. Using a 6 mm hexagon wrench, remove the 3 hexagon bolts, 3 plate washers, No. 1 EGR valve adapter, No. 2 EGR valve and 2 gaskets.

      A01BAHSE01

  30. REMOVE EGR COOLER INSULATOR


    1. A01BBOFE01

      Remove the 2 EGR cooler insulators from the EGR cooler.