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

    CAUTION:

    Do not remove the radiator reservoir cap sub-assembly 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.

      A003HILE01
      Text in Illustration
      *1 Bleeder Plug *2 Radiator Reservoir Cap Sub-assembly
      *3 Radiator Reservoir Assembly *4 Cylinder Block Drain Cock Plug
      *5 Radiator Drain Cock Plug - -

    2. Remove the radiator reservoir cap sub-assembly.

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

    4. Tighten the radiator drain cock plug.

    5. Tighten the cylinder block drain cock 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. A003E5J

      Disconnect the 2 water by-pass hoses.

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


    1. A003EXO

      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. A003BFQ

      Slide the 2 hose clamps and remove the water by-pass hose assembly from the water outlet and EGR cooler.

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


    1. A003GT7

      Slide the hose clamp and remove the No. 7 water by-pass hose from the No. 4 water by-pass pipe sub-assembly.

    2. Slide the hose clamp and remove the bolt and No. 4 water by-pass pipe sub-assembly from the No. 2 water by-pass hose.

  11. DISCONNECT WIRING HARNESS CONNECTOR


    1. A003CM0

      Disconnect the wiring harness connector and detach the clamp.

  12. REMOVE EGR VALVE BRACKET


    1. A003EO4

      Remove the 2 bolts and EGR valve bracket.

  13. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY


    1. A003HTA

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

    2. Remove the 2 gaskets.

  14. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A003GB5

      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. A003CL7

      Disconnect the vacuum control valve connector and 2 vacuum hoses from the No. 3 vacuum transmitting pipe sub-assembly.

    2. Remove the bolt and vacuum control valve set.

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


    1. A003FS7

      Disconnect the 2 vacuum hoses.

    2. Remove the 2 bolts and No. 3 vacuum transmitting pipe sub-assembly.

  17. DISCONNECT ENGINE ROOM MAIN WIRE


    1. A003G03

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

  18. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A003FUC

      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. A003C8F

      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. A003CIN

      Remove the bolt and gas filter bracket.

  22. REMOVE MANIFOLD STAY


    1. A003GG2

      Remove the 2 bolts and manifold stay.

  23. DISCONNECT NO. 3 WATER BY-PASS HOSE


    1. A003C4A

      Slide the hose clamp and disconnect the No. 3 water by-pass hose from the EGR cooler.

  24. REMOVE INTAKE AIR CONNECTOR ASSEMBLY


    1. A003AWZ

      Remove the 2 bolts and 2 nuts.

    2. A003EXE

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

  25. REMOVE INTAKE AIR TEMPERATURE SENSOR


    1. Disconnect the intake air temperature sensor connector.

    2. A003AY8E01

      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. A003C71

      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. A003C48

      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 assembly.

      A003G5Y

    2. Remove the gasket from the cylinder head sub-assembly.

  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 assembly and 2 gaskets.

      A003ECPE03
      Text in Illustration
      *1 EGR Cooler *2 No. 2 EGR Valve Assembly
      *3 No. 1 EGR Valve Adapter - -

  30. REMOVE EGR COOLER INSULATOR


    1. A003DG0E01
      Text in Illustration
      *1 No. 1 EGR Cooler Insulator
      *2 No. 2 EGR Cooler Insulator

      Remove the No. 1 EGR cooler insulator and No. 2 EGR cooler insulator from the EGR cooler.