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


    1. Remove the 4 bolts and 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

    A01DWMDE02

    1. Disconnect the mass air flow meter connector and remove the clamp.

    2. Loosen the hose clamp of the compressor inlet elbow.

    3. Remove the 2 bolts and air cleaner assembly.

  5. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A01DYO3

      Remove the 3 bolts, 2 nuts and 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. A01DXEZ

      for LHD:

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

    2. A01DXQXE01
      Text in Illustration
      *A for RHD
      *B for LHD

      Remove the bolt and ventilation pipe.

  8. REMOVE COMPRESSOR INLET ELBOW (for LHD)


    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 and No. 13 water by-pass hose.

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

    5. 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.

  9. REMOVE COMPRESSOR INLET ELBOW (for RHD)


    1. A01E1Y7

      Disconnect the 2 connectors and detach the wire harness clamp.

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

    3. A01E1F0

      Disconnect the 2 No. 1 turbo water hoses.

  10. DISCONNECT RADIATOR HOSE OUTLET


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

  11. DISCONNECT NO. 1 AUTOMATIC TRANSMISSION OIL COOLER TUBE CLAMP (for Automatic Transmission)

    A01DX6PE01

    1. Remove the bolt and disconnect the No. 1 automatic transmission oil cooler tube clamp.

  12. REMOVE WATER INLET

    A01DZUQE01

    1. Remove the 3 bolts and water inlet.

  13. REMOVE THERMOSTAT


    1. Remove the thermostat from the cylinder block.

    2. Remove the gasket from the thermostat.