THERMOSTAT (w/o DPF) REMOVAL


  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 FRONT FENDER APRON SEAL RH


    1. Using a clip remover, remove the 4 clips and front fender apron seal RH.

  6. REMOVE FRONT NO. 1 FENDER APRON TO FRAME SEAL RH


    1. Using a clip remover, remove the 5 clips and front No. 1 fender apron to frame seal RH.

  7. REMOVE UPPER RADIATOR SUPPORT SEAL


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

  8. REMOVE FRONT HEATER BRACKET (for Cold Area Specification Vehicles)


    1. A01DS63

      Remove the 2 bolts and front heater bracket.

  9. REMOVE FAN AND GENERATOR V BELT


    1. Using the pulley set bolt of the tensioner, rotate the tensioner pulley clockwise to loosen the belt tension. Then remove the V belt.

  10. REMOVE NO. 1 AIR CLEANER HOSE


    1. A01DNR2

      Loosen the 2 hose clamps and remove the No. 1 air cleaner hose.

  11. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    A01DTIXE02
    Text in Illustration
    *A except Cold Area Specification Vehicles
    *B for Cold Area Specification Vehicles

    1. except Cold Area Specification Vehicles:

      Detach the 2 clamps and disconnect the mass air flow meter connector.

    2. for Cold Area Specification Vehicles:

      Detach the 3 clamps and disconnect the mass air flow meter connector.

    3. Detach the 4 clamps and remove the air cleaner cap sub-assembly.

  12. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  13. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A01DMCQ

      Remove the 3 bolts and air cleaner case sub-assembly.

  14. REMOVE NO. 1 AIR HOSE


    1. A01DTFB

      Loosen the 2 clamps.

    2. Remove the No. 1 air hose from the inlet pipe and intercooler.

  15. REMOVE COMPRESSOR OUTLET ELBOW


    1. A01DTR4

      Detach the 3 wire harness clamps.

    2. Remove the bolt and wire harness bracket.

    3. A01DS15

      Loosen the hose clamp and remove the 2 bolts and compressor outlet elbow.

  16. REMOVE VISCOUS WITH MAGNET CLUTCH HEATER ASSEMBLY (for Cold Area Specification Vehicles)


    1. Disconnect the viscous heater connector.

    2. A01DP9N

      Disconnect the water by-pass hose and water hose.

    3. A01DRFR

      Remove the 2 bolts and viscous heater with magnet clutch.

  17. REMOVE VISCOUS HEATER NO. 1 BRACKET SUB-ASSEMBLY (for Cold Area Specification Vehicles)


    1. A01DQ4P

      Remove the 4 bolts and No. 1 viscous heater bracket.

  18. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)


    1. A01DR5G

      Disconnect the compressor connector.

    2. Remove the 4 bolts and disconnect the cooler compressor.

  19. REMOVE GENERATOR BRACKET


    1. A01DLWN

      Remove the bolt and generator bracket.

  20. REMOVE GENERATOR ASSEMBLY


    1. A01DT1P

      Disconnect the generator connector.

    2. Remove the terminal cap.

    3. Remove the nut and disconnect the generator wire.

    4. Remove the 2 bolts and generator.

  21. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A01DPQ1

      Remove the 5 bolts and No. 1 compressor mounting bracket.

  22. REMOVE VENTILATION PIPE


    1. A01DQZ6

      Type A

      Slide the 2 clamps and disconnect the No. 3 turbo water hose and No. 4 turbo water hose from the ventilation pipe.

    2. A01DM23E01
      Text in Illustration
      *A Type A
      *B Type B

      Remove the bolt and disconnect the 2 ventilation hoses and ventilation pipe from the cylinder head sub-assembly.

  23. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A01DT8L

      Remove the 2 bolts and engine oil level dipstick guide from the cylinder block sub-assembly.

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

  24. DISCONNECT NO. 2 RADIATOR HOSE


    1. A01DP14

      Slide the clamp and disconnect the No. 2 radiator hose.

  25. DISCONNECT NO. 2 WATER BY-PASS HOSE


    1. A01DLWC

      Disconnect the No. 2 water by-pass hose from the water inlet.

  26. REMOVE WATER INLET


    1. A01DSPG

      for Automatic Transmission:

      Remove the 2 bolts from the oil cooler tube clamp and bracket.

    2. A01DSPO

      Remove the 3 bolts and inlet.

  27. REMOVE THERMOSTAT


    1. Remove the thermostat.

    2. Remove the gasket from the thermostat.