EGR COOLER REMOVAL


  1. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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  2. REMOVE COWL BODY MOUNTING REINFORCEMENT LH (for LHD)


    1. A00436K

      Remove the 3 bolts and cowl body mounting reinforcement LH.

  3. REMOVE COWL BODY MOUNTING REINFORCEMENT RH (for RHD)


    1. A0042J0

      Remove the 3 bolts and cowl body mounting reinforcement RH.

  4. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)


    1. A0040EX

      Disengage the clamp and separate the wire harness.

    2. A0041QO

      Disengage the claw and bend the No. 1 heater air duct splash shield seal.

    3. A004113

      Disengage the claw and bend the water guard plate RH.

    4. A0043EB

      Remove the 9 bolts and outer cowl top panel sub-assembly.

  5. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)


    1. A0043SF

      Disengage the clamp and separate the wire harness from the outer cowl top panel sub-assembly.

    2. A00422BE01

      Disengage the clamp*1 and disconnect the connector (w/ Windshield Deicer).

    3. Disengage the clamp*2 and separate the wire harness from the outer cowl top panel sub-assembly.

    4. A0043QY

      Disengage the claw and bend the No. 1 heater air duct splash shield seal.

    5. A0043RA

      Disengage the claw and bend the water guard plate RH.

    6. A0041EP

      Remove the 9 bolts and outer cowl top panel sub-assembly.

  6. DRAIN COOLANT (for Engine)

    Note

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


    1. A0043WF

      Loosen the radiator drain cock plug.

      Tech Tips

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

    2. Remove the reserve tank cap and drain the coolant.

      A0041SAE01
      Text in Illustration
      *1 Reservoir Tank Cap *2 Radiator Drain Cock Plug

  7. REMOVE NO. 2 CYLINDER HEAD COVER


    1. A0042Q6

      Remove the 3 clips and No. 2 cylinder head cover.

      Note


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

      • Pull the cover straight up to remove. Attempting to pull the cover forward may cause it to break.

  8. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A0040W1

      Disconnect the mass air flow meter connector.

    2. A0040WOE01

      Release the 2 clamps.

    3. Loosen the hose clamp and remove the air cleaner cap sub-assembly.

  9. REMOVE INLET AIR CLEANER ASSEMBLY


    1. A0040MW

      Remove the 2 bolts and inlet air cleaner assembly.

  10. REMOVE AIR CLEANER CASE


    1. A0042F9

      Separate the No. 4 water by-pass hose from the air cleaner case.

    2. Remove the 3 bolts, 3 clamps and air cleaner case.

  11. REMOVE EGR PIPE ASSEMBLY


    1. A0042P5

      Disconnect the 2 wire harness clamps.

    2. A0042LP

      Remove the bolt and wire harness support.

    3. A004131

      Remove the 4 bolts, EGR pipe assembly and 2 gaskets.

  12. REMOVE EGR WITH COOLER PIPE SUB-ASSEMBLY


    1. A0043ZK

      Disconnect the connector, wire harness clamp and 4 water hoses.

    2. A00444ME01
      Text in Illustration
      *1 Stud Bolt and Nut

      Remove the 4 nuts and bolt.

    3. Using an E8 "TORX" socket wrench, remove the 4 stud bolts and EGR valve with cooler assembly.

    4. Remove the gasket.

    5. A0043W3

      Remove the 2 nuts, EGR with cooler pipe sub-assembly and gasket.