EGR COOLER (for DPF) REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the injection pipes and fuel inlet pipe, clean them with a brush and compressed air.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  2. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  3. REMOVE NO. 1 ENGINE UNDER COVER

  4. 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

  5. REMOVE FRONT WHEEL LH

  6. REMOVE FRONT FENDER APRON SEAL UPPER


    1. Remove the 5 clips and front fender apron seal upper.

  7. REMOVE FRONT FENDER SEAL


    1. Remove the 5 clips and front fender seal.

  8. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A01DXQT

      Detach the wire harness clamp.

    3. Remove the bolt and engine oil level dipstick guide.

    4. Remove the O-ring from the engine oil level dipstick guide.

  9. DISCONNECT WATER BY-PASS HOSE


    1. Disconnect the 6 water by-pass hoses.

      A01DYGI

  10. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE


    1. Disconnect the vacuum switching valve connector.

    2. Disconnect the 2 vacuum transmitting hoses.

    3. A01DZ34

      Remove the 2 bolts and manifold stay with vacuum switching valve.

  11. REMOVE NO. 3 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01E0TZ

      Remove the 3 bolts and No. 3 cylinder head cover.

  12. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A01DWTL

      Remove the bolt and No. 2 injection pipe clamp.

    2. Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.

  13. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Note


    • After removing the injection pipe, cover the outlets on the common rail with tape to keep out foreign matter.

    • After removing the injection pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.


    1. A01DZED

      Disconnect the 4 injector connectors and electric EGR control valve connector.

    2. Detach the 2 wire harness clamps.

    3. A01E1VL

      Remove the 4 nuts and 2 No. 3 injection pipe clamps.

    4. A01DXU8E01
      Text in Illustration
      *a Injector Side
      *b Common Rail Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

  14. REMOVE NO. 5 WATER BY-PASS PIPE


    1. A01E1P0

      Detach the 2 wire harness clamps.

    2. A01DY3N

      Disconnect the 2 water hoses from the electric EGR control valve.

    3. Remove the 2 bolts and No. 5 water by-pass pipe.

  15. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. A01DZNZ

      Disconnect the manifold absolute pressure sensor connector and vacuum hose.

    2. Remove the bolt and manifold absolute pressure sensor.

  16. REMOVE GAS FILTER BRACKET WITH GAS FILTER


    1. A01DX2C

      Disconnect the vacuum hose.

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

  17. REMOVE WIRING HARNESS CLAMP BRACKET


    1. A01E20E

      Remove the bolt and wiring harness clamp bracket.

  18. REMOVE THROTTLE BODY BRACKET


    1. A01DVNS

      Remove the 3 bolts and throttle body bracket.

  19. DISCONNECT ENGINE WIRE


    1. A01E2YK

      Detach the 2 wire harness clamps.

    2. Remove the bolt and disconnect the engine wire.

  20. DISCONNECT NO. 3 WATER BY-PASS PIPE


    1. A01E11O

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

  21. REMOVE EGR VALVE BRACKET


    1. A01DYLM

      Remove the 3 bolts and EGR valve bracket.

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


    1. A01DZHV

      Disconnect the fuel pressure sensor connector from the common rail.

    2. Remove the 5 bolts, 2 nuts and electric EGR control valve with No. 2 EGR valve and EGR cooler.

      A01E1DEE01
      Text in Illustration
      *1 Gasket - -

    3. Remove the 2 gaskets from the cylinder head and intake manifold.

  23. REMOVE INTAKE AIR CONNECTOR WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01DZNA

      Remove the 3 nuts, intake air connector with electric EGR control valve and gasket.

  24. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. Remove the electric EGR control valve and gasket from the intake air connector.

  25. REMOVE EGR VALVE ADAPTER


    1. A01DWYK

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

  26. REMOVE NO. 2 EGR VALVE ASSEMBLY


    1. A01DWST

      Remove the bolt, No. 2 EGR valve and gasket.

  27. REMOVE EGR COOLER INSULATOR


    1. A01DYVBE01
      Text in Illustration
      *1 No. 2 EGR Cooler Insulator
      *2 No. 1 EGR Cooler Insulator

      Remove the 2 EGR cooler insulators from the EGR cooler.