EGR COOLER REMOVAL


  1. DRAIN ENGINE COOLANT

    CAUTION:

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


    1. Connect a hose with an inside diameter of 9 mm (0.354 in.) to the radiator drain cock.

    2. Loosen the radiator drain cock plug.

      B007W5YE03
      Text in Illustration
      *1 Bleeder Plug *2 Radiator Cap Sub-assembly
      *3 Radiator Reserve Tank Assembly *4 Cylinder Block Drain Cock Plug
      *5 Radiator Drain Cock Plug - -

    3. Remove the radiator cap sub-assembly.

    4. Loosen the cylinder block drain cock plug, and drain the engine coolant.

    5. Tighten the radiator drain cock plug.

    6. Tighten the cylinder block drain cock plug.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    7. Disconnect the hose from the radiator drain cock.

  2. REMOVE SEAT TRACK COVER LH


    1. B007Q5Y

      Using a clip remover, remove the clip.

    2. Detach the claw and remove the seat track cover LH.

  3. REMOVE FRONT SEAT ASSEMBLY RH


    1. B007OW8

      Move the front seat assembly fully forward.

    2. Remove the 2 bolts on the rear side of the seat.

    3. Move the front seat assembly to the rearmost position.

    4. Remove the 2 bolts on the front side of the seat.

    5. Move the front seat assembly to the center of the seat slide rail. Set the seatback in the upright position.

    6. Disconnect the front seat inner belt assembly connector.

    7. Remove the front seat assembly.

  4. REMOVE FRONT DOOR SCUFF PLATE RH

  5. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Fold back the floor carpet.

    2. Remove the 5 bolts and engine service hole sub cover sub-assembly.

  6. REMOVE TRANSMISSION SERVICE HOLE COVER SUB-ASSEMBLY


    1. Remove the 2 seat belt anchor covers.

    2. B007TT6

      Remove the 2 bolts and disconnect the front center seat belt assembly RH and front center seat lap type belt assembly.

    3. Detach the clips and fold back the carpet.

    4. B007RB7

      Remove the 4 bolts and transmission service hole cover sub-assembly from the body.

  7. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  8. REMOVE NO. 16 WATER BY-PASS HOSE


    1. B007UJV

      Slide the 2 clamps and remove the No. 16 water by-pass hose from the No. 1 EGR cooler and No. 2 water by-pass pipe.

  9. REMOVE DIESEL TURBO PRESSURE SENSOR


    1. B007SSH

      Disconnect the connector from the diesel turbo pressure sensor.

    2. Remove the bolt and diesel turbo pressure sensor from the No. 3 water by-pass pipe sub-assembly.

  10. DISCONNECT ENGINE WIRE


    1. B007R53

      Detach the 2 clamps and disconnect the 2 connectors from the turbocharger sub-assembly.

    2. Disconnect the connector from the camshaft position sensor.

    3. B007QX2

      Detach the clamp and disconnect the connector from the differential pressure sensor.

    4. Disconnect the 3 connectors from the exhaust gas temperature sensors.

    5. Disconnect the connector from the exhaust fuel addition injector assembly.

    6. B007PUJ

      Disconnect the 4 connectors from the 4 injector assemblies.

    7. Disconnect the electric EGR control valve assembly.

    8. Disconnect the connector from the glow plug connector.

    9. Disconnect the connector from the sensor wire of common rail assembly.

    10. B007QL7

      Detach the 2 clamps and remove the 4 bolts.

    11. B007SWS

      Disconnect the connector from the swirl control valve.

    12. Disconnect the connector from the vacuum control valve set.

    13. Detach the 2 clamps and disconnect the engine wire from the engine assembly.

  11. REMOVE EGR VALVE BRACKET


    1. B007VJ5

      Remove the bolt, nut and EGR valve bracket from the electric EGR control valve assembly and intake manifold.

  12. REMOVE NO. 2 EGR PIPE


    1. B007TEN

      Remove the bolt, 4 nuts and No. 2 EGR pipe from the electric EGR control valve assembly and intake manifold.

    2. Remove the 2 gaskets.

  13. REMOVE NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. B007R0N

      Disconnect the No. 4 fuel hose from the No. 3 water by-pass pipe sub-assembly.

    2. B007QH0

      Slide the clamp and disconnect the No. 8 water by-pass hose from the No. 3 water by-pass pipe sub-assembly.

    3. Slide the clamp and disconnect the No. 9 water by-pass hose from the electric EGR control valve assembly.

    4. Remove the 2 bolts and No. 3 water by-pass pipe sub-assembly from the No. 1 EGR cooler.

  14. DISCONNECT NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. B007VVV

      Slide the clamp and disconnect the No. 7 water by-pass hose from the No. 1 EGR cooler.

    2. Slide the clamp and disconnect the water hose from the No. 2 EGR valve assembly.

    3. B007TLH

      Remove the 2 bolts and disconnect the No. 4 water by-pass pipe sub-assembly from the intake manifold.

  15. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY


    1. B007QH3

      Remove the bolt and disconnect the No. 1 EGR pipe sub-assembly from the vacuum transmitting pipe sub-assembly.

    2. B007PGN

      Remove the 4 nuts and the No. 1 EGR pipe sub-assembly from the exhaust manifold and EGR valve adapter.

    3. Remove the 2 gaskets.

    4. B007QR1

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold.

  16. REMOVE VACUUM CONTROL VALVE SET


    1. Disconnect the connector from the vacuum control valve set.

    2. B007SNQ

      Disconnect the 2 vacuum hoses from the vacuum control valve set and No. 2 EGR valve assembly.

    3. B007OKL

      Remove the 2 bolts and vacuum control valve set from the intake manifold.

  17. REMOVE NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. B007S1I

      Remove the 4 bolts and No. 1 EGR cooler and No. 2 EGR valve assembly with electric EGR control valve assembly from the intake manifold.

  18. REMOVE NO. 1 EGR COOLER


    1. B007PUD

      Remove the 4 bolts and No. 1 EGR cooler from the No. 2 EGR valve assembly with electric EGR control valve assembly.

    2. Remove the gasket.