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, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

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


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note


    • After turning the engine switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

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

  2. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  3. REMOVE UPPER RADIATOR SUPPORT SEAL


    1. Remove the 13 clips and upper radiator support seal.

  4. REMOVE FRONT BUMPER LOWER COVER


    1. Remove the clip, 5 bolts and front bumper lower cover.

  5. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. Remove the 4 bolts and No. 1 engine under cover.

  6. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Loosen the radiator drain cock plug.

      Tech Tips

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

    2. A01DPA5

      Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.

    3. Loosen the cylinder block drain cock plug.

      A01DNWCE01
      Text in Illustration
      *1 Radiator Reservoir *2 Vent Plug
      *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug

  7. REMOVE FRONT WHEEL LH

  8. REMOVE FRONT FENDER APRON SEAL LH


    1. Remove the 5 clips and front fender apron seal LH.

  9. REMOVE INJECTOR DRIVER ASSEMBLY


    1. A01DS6O

      Disconnect the 4 connectors.

    2. Remove the 2 bolts and injector driver assembly.

  10. DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A01DUMX

      Remove the 3 bolts and disconnect the vane pump oil reservoir.

  11. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE


    1. A01DTVF

      Disconnect the 3 vacuum switching valve connectors.

    2. A01DQV1

      Disconnect the No. 1 vacuum transmitting hose.

    3. A01DPF0

      Disconnect the 2 No. 2 vacuum transmitting hoses from the No. 2 EGR valve.

    4. A01DO5A

      Disconnect the No. 1 vacuum transmitting hose and No. 4 vacuum transmitting hose.

    5. A01DMMC

      Remove the 2 bolts and manifold stay with vacuum switching valve.

  12. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A01DT9L

      Remove the bolt and No. 2 injection pipe clamp.

    2. A01DUVSE01
      Text in Illustration
      *a Common Rail Side
      *b Fuel Supply Pump Side

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

  13. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Note


    • After removing the injection pipe, cover the outlets on the common rail with tape to keep out foreign matter.

    • After removing the injection pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.


    1. A01DN54

      Remove the 2 nuts and No. 3 injection pipe clamp.

    2. A01DOID

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

    3. A01DR7WE01
      Text in Illustration
      *a Injector Side
      *b Common Rail Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

  14. DISCONNECT HEATER WATER PIPE SUB-ASSEMBLY


    1. A01DSCK

      Detach the water by-pass hose clamp.

    2. Remove the bolt and disconnect the heater water pipe.

  15. REMOVE WATER BY-PASS HOSE


    1. Detach the 4 water by-pass hose clamps.

    2. Disconnect the No. 7 water by-pass hose labeled A in the illustration.

    3. Disconnect the No. 4 water by-pass hose labeled B in the illustration.

    4. Disconnect the No. 3 water by-pass hose labeled C in the illustration.

    5. Disconnect the No. 8 water by-pass hose labeled D in the illustration.

    6. Disconnect the No. 6 water by-pass hose labeled E in the illustration.

    7. Disconnect the No. 5 water by-pass hose labeled F in the illustration.

      A01DR6EE01

  16. REMOVE NO. 1 VACUUM TRANSMITTING PIPE


    1. A01DQGH

      Disconnect the vacuum hose from the intake manifold.

    2. Remove the bolt and No. 1 vacuum transmitting pipe.

  17. REMOVE WIRING HARNESS CLAMP BRACKET


    1. Disconnect the glow plug connector.

    2. A01DQ7X

      Detach the 2 wire harness clamps and disconnect the glow plug connector from the wiring harness clamp bracket.

    3. A01DTDD

      Remove the bolt and wiring harness clamp bracket.

  18. REMOVE NO. 3 ENGINE COVER BRACKET


    1. A01DU9H

      Remove the 2 nuts and No. 3 engine cover bracket.

  19. REMOVE ENGINE COVER BRACKET INSULATOR


    1. A01DU9R

      Remove the 2 nuts and 2 engine cover bracket insulators.

  20. REMOVE NO. 4 ENGINE COVER BRACKET


    1. A01DND6

      Remove the bolt and No. 4 engine cover bracket.

  21. REMOVE AIR CONNECTOR STAY


    1. A01DM1Y

      Disconnect the 4 injector connectors and detach the 3 wire harness clamps.

    2. A01DQ91E01
      Text in Illustration
      *1 No. 1 Fuel Pipe

      Remove the bolt labeled A and disconnect the No. 1 fuel pipe from the air connector stay.

    3. Remove the 3 bolts and air connector stay.

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


    1. A01DN1V

      Disconnect the fuel pressure sensor connector from the common rail.

    2. Remove the 4 nuts, 3 bolts and EGR cooler with No. 2 EGR valve.

    3. Remove the 2 gaskets from the cylinder head and electric EGR control valve.

      A01DO92E01
      Text in Illustration
      *1 Gasket - -

  23. REMOVE EGR VALVE ADAPTER


    1. A01DMXP

      Using a 6 mm hexagon wrench, remove the 3 hexagon bolts, 3 plate washers, EGR valve adapter and gasket.

  24. REMOVE NO. 2 EGR VALVE ASSEMBLY


    1. A01DRIC

      Remove the bolt, No. 2 EGR valve and gasket.

  25. REMOVE EGR COOLER INSULATOR


    1. A01DTXVE01
      Text in Illustration
      *1 No. 2 EGR Cooler Insulator
      *2 No. 1 EGR Cooler Insulator

      Remove the 2 EGR cooler insulators from the EGR cooler.