EGR COOLER REMOVAL

PROCEDURE

  1. DRAIN ENGINE COOLANT

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  2. REMOVE NO. 1 ENGINE COVER (w/ No. 1 Engine Cover)

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  3. REMOVE EGR BYPASS VALVE SWITCHING VALVE (NO. 1 VACUUM SWITCHING VALVE ASSEMBLY)

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  4. REMOVE EGR PIPE WITH COOLER SUB-ASSEMBLY

    1. A235723

      Disconnect the connector and disengage the wire harness clamp.

    2. A235724

      Disconnect the 2 connectors and remove the bolt.

    3. A235725

      Disconnect the vacuum transmitting hose and remove the bolt and manifold absolute pressure sensor (diesel turbo pressure sensor).

    4. A235726

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

    5. Slide the 2 clips and disconnect the No. 2 oil cooler hose and No. 2 water by-pass hose from the EGR pipe with cooler sub-assembly.

    6. A235727

      Remove the 4 bolts, 2 nuts and EGR pipe with cooler sub-assembly.

    7. Remove the 2 gaskets from the cylinder head and EGR valve (electric EGR control valve assembly).

    8. A235728

      Remove the bolt, 2 nuts and EGR pipe connector.

    9. Remove the 2 gaskets and No. 2 EGR valve assembly from the EGR pipe with cooler sub-assembly.

  5. REMOVE STUD BOLT

    Tip:

    If a stud bolt is deformed or the threads are damaged, replace it.

    1. A258787

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the EGR pipe with cooler sub-assembly.