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GSIC - Global Service Information Center

EGR COOLER > REMOVAL

for Preparation Click here



1. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

  1. Remove the windshield wiper motor and link assembly (Click here).



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


    C209143

  1. Remove the 3 bolts and cowl body mounting reinforcement LH.



3. REMOVE COWL BODY MOUNTING REINFORCEMENT LH (for RHD)


    C205554

  1. Remove the 3 bolts and cowl body mounting reinforcement LH.



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


    C205696

  1. Disengage the clamp and separate the wire harness.



    C209148

  1. Disengage the claw and bend the No. 1 heater air duct splash shield seal.



    C209146

  1. Disengage the claw and bend the water guard plate RH.



    C209144

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



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


    C205556

  1. Disengage the clamp and separate the wire harness from the outer cowl top panel sub-assembly.



    C205555E01

  1. Disengage the clamp*1 and disconnect the connector (w/ Windshield Deicer).

  1. Disengage the clamp*2 and separate the wire harness from the outer cowl top panel sub-assembly.



    C205558

  1. Disengage the claw and bend the No. 1 heater air duct splash shield seal.



    C205560

  1. Disengage the claw and bend the water guard plate RH.



    C205557

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



6. DRAIN COOLANT (for Engine)

NOTICE:
Do not remove the reservoir tank cap, cylinder block drain cock plugs 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 and drain the coolant.


    A251110E01


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

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



7. REMOVE NO. 2 CYLINDER HEAD COVER


    A213020

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

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

    NOTICE:
    Attempting to disengage both front and rear clips at the same time may cause the cover to break.



8. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    A212311

  1. Disconnect the connector.



    A288960

  1. Loosen the hose clamp and disconnect the air cleaner hose assembly.

  1. Remove the 2 clamps and air cleaner cap sub-assembly.



9. REMOVE INLET AIR CLEANER ASSEMBLY


    A269507

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



10. REMOVE AIR CLEANER CASE

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



    A212314

  1. Separate the hose from the 3 clamps.

  1. Remove the 3 bolts and air cleaner case.



11. 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.



12. 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" 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.