EGR COOLER (w/o 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.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note


    • After turning the ignition 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 FRONT BUMPER LOWER COVER


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

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


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

  4. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator 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.

      A01DNO9E01
      Text in Illustration
      *1 Radiator Reservoir *2 Vent Plug
      *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug

  5. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. Remove the cowl top ventilator louver Click here.

  6. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. Remove the diesel throttle body Click here.

  7. DISCONNECT NO. 3 WATER BY-PASS HOSE


    1. A01DMQP

      Remove the clamp.

    2. Disconnect the No. 3 water by-pass hose from the EGR cooler.

  8. DISCONNECT NO. 4 WATER BY-PASS HOSE


    1. Disconnect the No. 4 water by-pass hose from the EGR cooler.

  9. REMOVE INJECTION PIPE

    Note


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

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


    1. A01DT2A

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

    2. A01DUQA

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

    3. A01DO1DE01
      Text in Illustration
      *a for Injector Side
      *b for 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.

  10. REMOVE AIR CONNECTOR STAY


    1. A01DRSE

      Remove the 3 bolts and air connector stay.

  11. DISCONNECT ENGINE WIRE (for LHD)


    1. A01DTKF

      Remove the 2 bolts.

    2. Detach the clamp and disconnect the engine wire.

  12. DISCONNECT ENGINE WIRE (for RHD)


    1. A01DOK7

      Remove the bolt and disconnect the engine wire.

  13. REMOVE EGR VALVE BRACKET


    1. Remove the 2 nuts and EGR valve bracket.

  14. REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY


    1. A01DRXH

      Disconnect the 2 connectors from the electric EGR control valve and E-VRV.

    2. A01DOAO

      Detach the wire harness clamp.

    3. A01DOLL

      Disconnect the 5 vacuum hoses.

    4. Remove the bolt and gas filter together with the gas filter bracket.

    5. A01DT6Y

      Remove the 2 bolts and E-VRV bracket together with the EGR vacuum damper.

  15. REMOVE NO. 2 INTAKE AIR CONNECTOR


    1. A01DPM6

      Remove the 3 nuts, No. 2 intake air connector and gasket.

  16. REMOVE INTAKE AIR CONNECTOR


    1. A01DOLG

      Remove the 3 bolts, intake air connector and 2 gaskets.

  17. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER


    1. A01DMW6

      Disconnect the No. 3 vacuum transmitting hose from the No. 2 EGR valve.

    2. A01DOVN

      Remove the bolt, 2 nuts, electric EGR control valve together with the No. 2 EGR valve and EGR cooler.

    3. Remove the gasket from the cylinder block.

  18. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01DSG4E01
      Text in Illustration
      *A w/ EGR Cooler
      *B w/o EGR Cooler

      Remove the 2 bolts, electric EGR control valve and gasket.

  19. REMOVE EGR VALVE ADAPTER


    1. A01DTMG

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

  20. REMOVE NO. 2 EGR VALVE ASSEMBLY


    1. A01DPOB

      Using a 5 mm hexagon wrench, remove the hexagon bolt, No. 2 EGR valve and gasket.

  21. REMOVE EGR COOLER

    A01DPTN