EGR COOLER REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

  2. DRAIN ENGINE COOLANT

    CAUTION:

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


    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. A01DY58E01

      Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.

    3. Loosen the cylinder block drain cock plug.

      A01E07NE01

  3. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. Remove the diesel throttle body Click here.

  4. DISCONNECT NO. 3 WATER BY-PASS HOSE


    1. A01DVEQ

      Remove the clamp.

    2. Disconnect the No. 3 water by-pass hose from the EGR cooler.

  5. DISCONNECT NO. 4 WATER BY-PASS HOSE


    1. Disconnect the No. 4 water by-pass hose from the EGR cooler.

  6. REMOVE INJECTION PIPE


    1. A01DZ04

      Remove the injection pipe No. 1, 2 and 3 Click here.

  7. REMOVE VENTURI BRACKET


    1. A01E1G1

      Remove the 3 bolts and venturi bracket.

  8. DISCONNECT NO. 3 WATER BY-PASS PIPE


    1. A01DZCR

      Remove the 2 bolts and disconnect the No. 3 water by-pass pipe with wire harness.

  9. REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY


    1. A01DWY1

      Disconnect the 2 connectors from the electric EGR control valve and E-VRV.

    2. A01DV5Q

      Disconnect the 5 vacuum hoses.

    3. Remove the bolt and gas filter with the gas filter bracket.

    4. A01DZX0

      Remove the 2 bolts and E-VRV's bracket with EGR vacuum damper.

  10. REMOVE NO. 2 INTAKE AIR CONNECTOR


    1. A01DZS6

      Remove the 3 nuts, No. 2 intake air connector and gasket.

  11. REMOVE INTAKE AIR CONNECTOR


    1. A01DW3T

      Remove the 3 bolts, intake air connector and 2 gaskets.

  12. REMOVE ELECTRIC EGR CONTROL VALVE WITH NO. 2 EGR VALVE AND EGR COOLER


    1. A01E2RS

      Disconnect the vacuum hose from the No. 2 EGR valve.

    2. A01E119

      Remove the bolt, 2 nuts, electric EGR control valve with the No. 2 EGR valve and EGR cooler.

    3. Remove the gasket from the cylinder block.

  13. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01E13P

      Remove the 2 bolts, electric EGR control valve and gasket.

  14. REMOVE EGR VALVE ADAPTER


    1. A01DYFCE01

      Using a 6 mm hexagon wrench, remove the 3 hexagon bolts, 3 plate washers, EGR valve adapter and gasket.

  15. REMOVE NO. 2 EGR VALVE ASSEMBLY


    1. A01E2TZ

      Using a 5 mm hexagon wrench, remove the hexagon bolt, No. 2 EGR valve and gasket.

  16. REMOVE EGR COOLER

    A01DZUP