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)


    1. Remove the 4 bolts and No. 1 engine under cover.

  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. for Ventilation Hose Type:

      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 WITH INTAKE AIR CONNECTOR


    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 COMPRESSOR INLET ELBOW


    1. A01DXDA

      for Ventilation Pipe Type:

      Remove the bolt and disconnect the 2 ventilation hoses and ventilation pipe.

    2. A01E2BV

      Detach the wire harness clamp.

    3. Remove the 2 nuts, inlet elbow and gasket.

  8. DISCONNECT RADIATOR HOSE INLET

  9. REMOVE WATER INLET

    A01DZUQE01

    1. Remove the 3 bolts and water inlet.

  10. REMOVE THERMOSTAT