EGR COOLER REMOVAL


  1. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator cap sub-assembly or radiator drain cock plug while the engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. B000JZIE01
      Text in Illustration
      *1 Engine Under Cover LH
      *a Hose

      Connect a hose with an inside diameter of 9 mm (0.354 in.) to the radiator drain cock as shown in the illustration.

    2. Loosen the radiator drain cock plug.

    3. B000I0KE01
      Text in Illustration
      *1 Radiator Cap Sub-assembly
      *2 Radiator Drain Cock Plug

      Remove the radiator cap sub-assembly. Then drain the engine coolant.

      Tech Tips

      Collect the engine coolant in a container and dispose of it according to the regulations in your area.

    4. Disconnect the hose from the radiator drain cock.

  2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. B000KZ3

      Disengage the 3 grommets to remove the No. 1 engine cover sub-assembly.

      Note

      When removing the No. 1 engine cover sub-assembly, make sure to lift it upward. Pulling the No. 1 engine cover sub-assembly towards you may damage the No. 1 engine cover sub-assembly.

  3. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE


    1. B000K14

      Slide the clip and disconnect the ventilation hose from the cylinder head cover sub-assembly.

    2. Disengage the ventilation hose clamp.

    3. B000K4H

      Disconnect the mass air flow meter sub-assembly connector.

    4. Disengage the wire harness clamp.

    5. B000JRQ

      Disconnect the union to connector tube hose from the air cleaner hose sub-assembly.

    6. Disengage the 2 air cleaner cap clamps and 2 guides.

    7. B000L1M

      Loosen the hose clamp and remove the air cleaner cap with air cleaner hose from the throttle body with motor assembly.

  4. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.

  5. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. B000LJY

      Disconnect the wire harness clamp.

    2. Remove the 2 bolts and air cleaner case sub-assembly.

  6. REMOVE FUEL PUMP PROTECTOR


    1. B000MEM

      Remove the 2 bolts and fuel pump protector from the cylinder head cover sub-assembly.

  7. REMOVE EGR PIPE CONNECTOR


    1. B000JFS

      Remove the 4 bolts, nut and EGR pipe connector from the exhaust manifold converter sub-assembly (TWC: Front Catalyst), EGR cooler assembly and cylinder block sub-assembly.

      Text in Illustration
      B000K70 Bolt
      B000IB9 Nut
    2. B000L15

      Remove the 2 EGR cooler gaskets from the EGR pipe connector.

  8. REMOVE NO. 2 EGR PIPE


    1. B000M5N

      Disengage the 2 wire harness clamps from the No. 2 EGR pipe.

    2. B000MGH

      Remove the 4 bolts and No. 2 EGR pipe from the EGR valve assembly and intake manifold.

    3. B000HBI

      Remove the No. 2 EGR pipe gasket from the EGR valve assembly.

    4. B000KK2

      Remove the EGR inlet gasket from the intake manifold.

  9. DISCONNECT ENGINE WIRE


    1. B000I7EE01
      Text in Illustration
      *a Fuel Pump Sub-assembly Connector
      *b Ignition Coil Assembly Connector
      *c Camshaft Position Sensor Connector
      B000K70 Bolt
      B000IB9 Nut

      Remove the 2 bolts and disconnect the 2 earth wires from the EGR valve bracket.

    2. Remove the nut.

    3. Disconnect the 2 camshaft position sensor connectors.

    4. Disconnect the ignition coil assembly connector.

    5. Disconnect the fuel pump sub-assembly connector.

    6. Disengage the clamp.

    7. B000MOF

      Remove the bolt.

    8. Disconnect the engine coolant temperature sensor connector.

  10. REMOVE EGR VALVE WITH COOLER ASSEMBLY


    1. B000HLO

      Disconnect the EGR valve assembly connector.

    2. B000IE5

      Remove the engine cover joint and separate the fuel hose bracket from the EGR valve bracket.

    3. B000JNF

      Remove the 4 bolts and 2 EGR valve brackets.

    4. B000I48

      Disengage the water hose from the hose clamp.

    5. B000HQE

      Slide the clip and disconnect the water hose sub-assembly from the EGR cooler assembly.

    6. B000I5ME01
      Text in Illustration
      *1 No. 2 Water By-pass Hose
      *2 No. 3 Water By-pass Hose
      *3 No. 4 Water By-pass Hose

      Slide the clip and disconnect the No. 2 water by-pass hose from the EGR valve assembly.

    7. Slide the clip and disconnect the No. 3 water by-pass hose from the EGR cooler assembly.

    8. Slide the clip and disconnect the No. 4 water by-pass hose from the EGR cooler assembly.

    9. B000NPA

      Remove the 2 nuts and EGR valve with cooler assembly from cylinder head sub-assembly.

    10. B000H11

      Remove the No. 2 EGR pipe gasket from the EGR valve assembly.

  11. REMOVE EGR COOLER ASSEMBLY


    1. B000JMJ

      Slide the clip and disconnect the No. 1 water by-pass hose from the EGR cooler assembly.

    2. B000MBA

      Remove the 2 nuts and EGR cooler assembly from the EGR valve assembly.

    3. B000IAF

      Remove the EGR valve gasket from the EGR valve assembly.