THERMOSTAT (w/ 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. REMOVE NO. 1 ENGINE UNDER COVER (for 4WD)

  3. 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

  4. REMOVE AIR CLEANER ASSEMBLY


    1. w/o EGR Cooler:

      Disconnect the ventilation hose.

    2. w/ Mass Air Flow Meter:

      Disconnect the mass air flow meter sensor connector.

    3. w/ Intake Air Temperature Sensor:

      Disconnect the intake air temperature sensor connector.

    4. Loosen the hose clamp.

    5. Remove the 2 bolts and air cleaner.

  5. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A01E1YJ

      Remove the 3 bolts, 2 nut and engine cover.

  6. REMOVE INTERCOOLER ASSEMBLY


    1. A01DY9J

      Detach the 2 clamps.

    2. Disconnect the vacuum hose from the manifold absolute pressure sensor.

    3. Disconnect the IAT sensor connector and manifold absolute diesel pressure sensor connector.

    4. A01DXPG

      Loosen the 2 hose clamps of the No. 1 air hose.

    5. A01DV5L

      Loosen the 2 hose clamps of the No. 2 air hose.

    6. A01DZT1

      Remove the 4 bolts and intercooler.

  7. REMOVE VENTILATION PIPE


    1. A01DV0H

      for Waste Gate Type Turbocharger:

      Remove the bolt and ventilation pipe.

    2. for Variable Nozzle Vane Turbocharger:


      1. A01DXEZ

        Disconnect the No. 12 water by-pass hose and No. 13 water by-pass hose.

      2. A01DXFZ

        Remove the bolt and ventilation pipe.

  8. REMOVE COMPRESSOR INLET ELBOW (for Waste Gate Type Turbocharger)


    1. A01DYHT

      Loosen the clamp, and then remove the compressor inlet elbow and air cleaner hose assembly from the turbocharger sub-assembly.

    2. Loosen the clamp, remove the air cleaner hose assembly from the compressor inlet elbow.

    3. Remove the No. 3 air cleaner hose from the turbo charger sub-assembly.

  9. REMOVE COMPRESSOR INLET ELBOW (for Variable Nozzle Vane Turbocharger)


    1. A01E1Y7

      Disconnect the 2 connectors and detach the wire harness clamp.

    2. A01DX8N

      Disconnect the No. 1 turbo water hose.

    3. A01E0Z9E01
      Text in Illustration
      *1 No. 2 Water By-pass Hose
      *2 No. 13 Water By-pass Hose

      Disconnect the No. 2 water by-pass hose.

    4. Remove the No. 12 water by-pass hose and No. 13 water by-pass hose.

    5. Remove the 2 nuts, compressor inlet elbow and gasket.

    6. A01DXHHE01
      Text in Illustration
      *1 No. 7 Water By-pass Hose
      *2 No. 12 Water By-pass Hose

      Remove the No. 7 water by-pass hose and No. 12 water by-pass hose.

  10. DISCONNECT RADIATOR HOSE OUTLET


    1. Disconnect the radiator hose outlet from the water inlet.

  11. REMOVE WATER INLET

    A01DZUQE01

    1. Remove the 3 bolts and water inlet.

  12. REMOVE THERMOSTAT


    1. Remove the thermostat from the cylinder block.

    2. Remove the gasket from the thermostat.