EGR COOLER REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the EGR cooler removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedures Effects/Inoperative when not Performed Link
Replacement of diesel throttle body assembly Perform initialization -
Replacement of electric EGR control valve assembly Perform initialization -

CAUTION:

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

B0068EY

PROCEDURE


  1. DRAIN ENGINE COOLANT

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  2. REMOVE DIESEL THROTTLE BODY ASSEMBLY

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  3. REMOVE NO. 2 WATER BY-PASS PIPE

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  4. REMOVE GAS FILTER

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  5. REMOVE TURBO PRESSURE SENSOR

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  6. REMOVE NO. 2 HOSE TO HOSE TUBE

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  7. REMOVE NO. 2 ENGINE COVER BRACKET

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  8. DISCONNECT FUEL FILTER ASSEMBLY

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

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  10. REMOVE NO. 1 UREA TANK FILLER PIPE SUPPORT (w/ Urea SCR System)

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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. DISCONNECT NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.


    1. B00294Q

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

    2. B0026HW

      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 EGR PIPE WITH COOLER SUB-ASSEMBLY (w/ DPF)

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  17. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY (w/o DPF)

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  18. REMOVE VACUUM CONTROL VALVE SET

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

    CAUTION:

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.


    1. B00269H

      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.

  20. REMOVE NO. 1 EGR COOLER


    1. B0025KC

      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.