EGR COOLER REMOVAL

PROCEDURE


  1. DRAIN ENGINE COOLANT

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  2. REMOVE DIESEL THROTTLE BODY ASSEMBLY

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  3. REMOVE WATER HOSE SUB-ASSEMBLY

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  4. REMOVE NO. 2 WATER BY-PASS PIPE

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  5. REMOVE GAS FILTER

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  6. REMOVE DIESEL TURBO PRESSURE SENSOR

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  7. REMOVE NO. 3 ENGINE COVER BRACKET

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  8. REMOVE NO. 2 ENGINE COVER BRACKET

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  9. DISCONNECT UREA TANK FILLER PIPE ASSEMBLY (w/ Urea SCR System)

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  10. DISCONNECT VANE PUMP OIL RESERVOIR SUB-ASSEMBLY

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  11. DISCONNECT ENGINE WIRE

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  12. REMOVE EGR VALVE BRACKET

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  13. REMOVE NO. 2 EGR PIPE

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  14. REMOVE NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. B001EXQ

      Disconnect the No. 4 fuel hose from the No. 3 water by-pass pipe sub-assembly.

    2. B001EX2

      Slide the clamp and disconnect the No. 8 water by-pass hose from the No. 3 water by-pass pipe sub-assembly.

    3. Slide the clamp and disconnect the No. 9 water by-pass hose from the electric EGR control valve assembly.

    4. Remove the 2 bolts and No. 3 water by-pass pipe sub-assembly from the No. 1 EGR cooler.

  15. DISCONNECT NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY

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  16. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

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  17. REMOVE VACUUM CONTROL VALVE SET

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  18. REMOVE NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. B001IKD

      Remove the 4 bolts and No. 1 EGR cooler and No. 2 EGR valve assembly with electric EGR control valve assembly from the intake manifold.

  19. REMOVE NO. 1 EGR COOLER


    1. B001G95

      Remove the 4 bolts and No. 1 EGR cooler from the No. 2 EGR valve assembly with electric EGR control valve assembly.

    2. Remove the gasket.