EGR COOLER REMOVAL

PROCEDURE


  1. PRECAUTION

    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.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  3. DISCONNECT CABLE FROM POSITIVE BATTERY TERMINAL

  4. REMOVE NO. 1 ENGINE UNDER COVER

    Click here

  5. DRAIN ENGINE COOLANT

    Click here

  6. REMOVE RADIATOR SUPPORT OPENING COVER

    Click here

  7. REMOVE BATTERY CLAMP SUB-ASSEMBLY

    Click here

  8. REMOVE BATTERY INSULATOR

  9. REMOVE BATTERY

  10. REMOVE BATTERY TRAY

  11. REMOVE BATTERY CARRIER

    Click here

  12. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY

    Click here

  13. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  14. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  15. DISCONNECT COMPRESSOR OUTLET ELBOW

    Click here

  16. DISCONNECT ENGINE WIRE

    Click here

  17. REMOVE NO. 4 WATER BY-PASS HOSE

    Click here

  18. DISCONNECT NO. 1 AIR TUBE ASSEMBLY

    Click here

  19. DISCONNECT FUEL FEED PIPE SUB-ASSEMBLY


    1. A004QQP

      Detach the 2 clamps and disconnect the engine wire.

    2. A004SCN

      Remove the 2 bolts and disconnect the fuel feed pipe sub-assembly.

    3. A004RN6

      Disconnect the vacuum hose from the No. 2 fuel hose.

    4. Disconnect the fuel feed pipe sub-assembly from the fuel pipe clamp.

  20. REMOVE NO. 1 TURBO INSULATOR

    Click here

  21. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A004SRB

      Disconnect the air fuel ratio sensor connector.

    2. Raise the air fuel ratio sensor connector to remove the air fuel ratio sensor connector from the bracket.

    3. Detach the 2 clamps and disconnect the air fuel ratio sensor.

    4. Detach the 2 clamps and disconnect the engine wire.

  22. REMOVE EGR COOLER ASSEMBLY WITH EGR VALVE ASSEMBLY


    1. A004T3G

      Disconnect the EGR valve assembly connector.

    2. Detach the clamp and disconnect the engine wire from the EGR valve assembly.

    3. Disconnect the hose clamp from the EGR cooler hose.

    4. A004TGX

      Disconnect the vacuum hose from the EGR cooler assembly.

    5. A004NNYE02

      Remove the 7 bolts and EGR cooler assembly with EGR valve assembly.

      Tech Tips


      • When removing the bolts labeled A, use a T45 "TORX" socket wrench.

      • When removing the bolts labeled B, use a 6 mm hexagon wrench.

      • The bolt labeled C in the illustration cannot be removed from the intake manifold.

    6. Remove the gasket.

    7. A004TJ3

      Remove the water pipe from the EGR cooler assembly.

  23. REMOVE EGR VALVE ASSEMBLY

    Click here