EGR COOLER (w/o DPF) REMOVAL


  1. REMOVE NO. 1 ENGINE UNDER COVER (for Cold Area Specification Vehicles)


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

  2. REMOVE NO. 2 ENGINE UNDER COVER (for Cold Area Specification Vehicles)


    1. Remove the 6 bolts and No. 2 engine under cover.

  3. 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 }

  4. REMOVE NO. 2 ENGINE SERVICE HOLE COVER (for Standard Body)

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


    1. A003D9DE02

      Remove the 2 bolts and transmission oil filler tube sub-assembly.

    2. Remove the O-ring from the oil filler tube sub-assembly.

  6. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  7. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A003BYL

      Remove the bolt and engine oil level dipstick guide.

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

  8. DISCONNECT NO. 1 GAS FILTER


    1. A003CAQ

      Remove the bolt and disconnect the vacuum hose together with the No. 1 gas filter.

  9. REMOVE VACUUM SWITCHING VALVE ASSEMBLY


    1. A003F4V

      Disconnect the connector from the electric EGR control valve.

    2. Detach the clamp and wire harness.

    3. A003CLZ

      Disconnect the connector and vacuum hose from the vacuum switching valve.

    4. Remove the bolt and vacuum switching valve.

  10. REMOVE MANIFOLD STAY


    1. A003AIN

      Remove the 2 bolts and manifold stay.

  11. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. Remove the 2 bolts and disconnect the No. 2 EGR pipe from the No. 2 EGR valve and gasket.

    2. Remove the bolt and 2 nuts, disconnect the electric EGR control valve together with the intake air connector from the intake manifold and remove the gasket.

    3. Remove the electric EGR control valve and gasket from the intake air connector.

    4. A003I96

      Disconnect the connector from the vacuum regulating valve.

    5. Disconnect the 2 vacuum hoses from the vacuum regulating valve.

    6. Remove the 2 bolts and vacuum regulating valve.

  12. DISCONNECT NO. 4 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A003EFB

      Disconnect the No. 4 vacuum transmitting hose from the EGR cooler.

  13. DISCONNECT WATER BY-PASS HOSE ASSEMBLY


    1. A003BN5

      Disconnect the water by-pass hose from the EGR cooler.

  14. DISCONNECT NO. 4 WATER BY-PASS HOSE

    A003AJU

  15. REMOVE EGR COOLER ASSEMBLY


    1. A003HH5

      Remove the 2 bolts, 2 nuts and No. 1 EGR pipe together with the No. 2 EGR valve and EGR cooler.

    2. Remove the gasket from the cylinder head.

  16. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY


    1. A003G9S

      Remove the 2 nuts, No. 1 EGR pipe and gasket.