DIESEL THROTTLE BODY REMOVAL


  1. REMOVE ENGINE ROOM SIDE COVER


    1. A003B3G

      Remove the clip and engine room side cover.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note


    • w/ Navigation System (for HDD):

      After the ignition switch is turned off, the HDD navigation system requires approximately a minute to record various types of memory and settings. As a result, after turning the ignition switch off, wait a minute or more before disconnecting the cable from the negative (-) battery terminal.

    • When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  3. REMOVE NO. 1 ENGINE COVER


    1. A003DQW

      Hold the rear of the cover and slowly raise it to detach the clip on the rear of the cover. Continue to raise the cover to detach the 3 clips on the front and side of the cover and remove the cover.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the cover to break.

  4. REMOVE RADIATOR SUPPORT OPENING COVER


    1. A003AXU

      Remove the 8 clips and radiator support opening cover.

  5. REMOVE FRONT LOWER BUMPER ABSORBER


    1. A003EIP

      Remove the 4 screws and 2 bolts.

    2. A003ALH

      Remove the 8 bolts and 3 screws.

    3. Detach the 2 hooks of the front lower bumper absorber from the installation holes on the body and remove the front lower bumper absorber.

  6. REMOVE ENGINE UNDER COVER


    1. A003BQH

      Remove the 11 clips and engine under cover.

  7. DRAIN ENGINE COOLANT


    1. Loosen the radiator drain cock plug.

      Tech Tips

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

    2. Remove the radiator reservoir cap.

      CAUTION:

      Do not remove the radiator reservoir cap and air release plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    3. Loosen the cylinder block drain cock plug. Then drain the coolant from the engine.

      Tech Tips

      The plug is on the backside of the generator on the EGR cooler side.

      A00OSDBE01
      Text in Illustration
      *1 Radiator Reservoir Cap *2 Air Release Plug
      *3 Cylinder Block Drain Cock Plug (Type A) *4 Cylinder Block Drain Cock Plug (Type B)
      *5 Radiator Drain Cock Plug - -

  8. REMOVE NO. 3 AIR HOSE


    1. A003DCT

      Loosen the 2 hose clamps.

    2. Remove the No. 3 air hose from the No. 2 air tube and diesel throttle body.

  9. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A003B2E

      Disconnect the No. 7 water by-pass hose from the throttle body.

    2. Disconnect the No. 6 water by-pass hose from the throttle body.

    3. Disconnect the throttle position sensor and throttle motor connector.

    4. A003C3E

      Remove the 2 nuts, 2 bolts, diesel throttle body and gasket.