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EGR COOLER > REMOVAL

for Preparation Click here



1. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
(Click here)


2. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)


    C232358

  1. Disengage the 2 claws and remove the No. 1 heater air duct splash shield seal.



3. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)


    C232376

  1. Disengage the 2 claws and remove the No. 1 heater air duct splash shield seal.



4. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)


    C232367

  1. Disengage the claw and guide, and remove the No. 2 heater air duct splash shield seal.



5. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)


    C232375

  1. Disengage the claw and guide, and remove the No. 2 heater air duct splash shield seal.



6. REMOVE COWL BODY MOUNTING REINFORCEMENT LH (for LHD)


    C232357

  1. Remove the 2 bolts and cowl body mounting reinforcement LH.



7. REMOVE COWL BODY MOUNTING REINFORCEMENT RH (for RHD)


    C232377

  1. Remove the 2 bolts and cowl body mounting reinforcement RH.



8. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)


    C232360

  1. Disengage the clamp and separate the wire harness.



    C232359

  1. w/ Wiper Deicer:
    Disengage the 3 clamps, disconnect the connector and separate the wire harness.



    C232361

  1. Remove the 9 bolts and outer cowl top panel sub-assembly.



9. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)


    C232378

  1. Disengage the clamp and separate the wire harness.



    C232379

  1. w/ Wiper Deicer:
    Disengage the 3 clamps, disconnect the connector and separate the wire harness.



    C232380

  1. Remove the 9 bolts and outer cowl top panel sub-assembly.



10. DRAIN COOLANT (for Engine)

NOTICE:
Do not remove the reserve tank cap and radiator drain cock plug 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.

    HINT:
    Collect the coolant in a container and dispose of it according to the local regulations.



  1. Remove the reserve tank cap and drain the coolant.


    A251091E01


    Text in Illustration 
    *1
    		Reserve Tank Cap
    		*2
    		Radiator Drain Cock Plug



11. REMOVE NO. 2 CYLINDER HEAD COVER


    A248095E01

  1. Remove the 3 clips and No. 2 cylinder head cover.

    NOTICE:
    1. Disengage the clips in the order shown in the illustration.
    2. Attempting to disengage both front and rear clips at the same time may cause the cover to break.
    3. Pull the cover straight up to remove. Attempting to pull the cover forward may cause it to break.



12. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    A247952

  1. Disconnect the mass air flow meter connector.



    A247953

  1. Separate the water hose from the hose clamp.

  1. Release the 2 clamps.

  1. Loosen the hose clamp and remove the air cleaner cap.



13. REMOVE INLET AIR CLEANER ASSEMBLY


    A247954

  1. Separate the water hose from the hose clamp.



    A247955

  1. Separate the wire harness clamp from the inlet air cleaner assembly.

  1. Remove the 2 bolts, 2 clips and inlet air cleaner assembly.



14. REMOVE AIR CLEANER CASE

  1. Remove the air cleaner filter element sub-assembly.



    A247956

  1. Separate the hose from the hose clamp.

  1. Remove the 2 bolts and air cleaner case.



15. REMOVE EGR PIPE ASSEMBLY


    A212663

  1. Disconnect the 2 wire harness clamps.



    A212664

  1. Remove the bolt and wire harness support.



    A212665

  1. Remove the 4 bolts, EGR pipe assembly and 2 gaskets.



16. REMOVE EGR COOLER SUB-ASSEMBLY


    A212666

  1. Disconnect the connector, wire harness clamp and 4 water hoses.



    A212667E01

  1. Remove the 4 nuts and bolt.
    Text in Illustration 
    *1
    		Stud Bolt and Nut

  1. Using an E8 "TORX" socket wrench, remove the 4 stud bolts and EGR valve with cooler assembly.

  1. Remove the gasket.



    A212669

  1. Remove the 2 nuts, EGR cooler sub-assembly and gasket.