REMOVAL AND INSTALLATION


<Except Euro5>


Pre-removal Operation
  • Under Skid Plate and Engine Room Under Cover Removal (Refer to GROUP 51 - Under Cover ).
  • Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Battery and Battery Box Removal (Refer to 54A - Battery ).

 Post-installation Operation
  • Battery and Battery Box Installation (Refer to 54A - Battery ).
  • Engine Coolant Refilling (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Under Skid Plate and Engine Room Under Cover Installation (Refer to GROUP 51 - Under Cover ).




Removal steps


1.
 Engine cover


2.
 Wiring harness connection


3.
 Engine oil level gauge and guide assembly


4.
 O-ring


5.
 Transmission fluid level gauge and guide assembly <A/T>


6.
 O-ring <A/T>


7.
 EGR valve

>>B<<
 8.
 EGR valve gasket

>>A<<
 9.
 EGR pipe gasket


10.
 EGR pipe B

>>A<<
 11.
 EGR pipe gasket


12.
 EGR pipe heat protector


13.
 EGR pipe A

>>A<<
 14.
 EGR pipe gasket

>>A<<
 15.
 EGR pipe gasket


16.
 Water hose


17.
 Heater piping hose connection


18.
 EGR cooler


19.
 EGR cooler bracket

<Euro5>


Pre-removal Operation
  • Engine Cover Removal (Refer to GROUP 11A - Engine Assembly ).
  • Under Skid Plate and Engine Room Under Cover Removal (Refer to GROUP 51 - Under Cover ).
  • Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Battery and Battery Box Removal (Refer to 54A - Battery ).

 Post-installation Operation
  • Battery and Battery Box Installation (Refer to 54A - Battery ).
  • Engine Coolant Refilling (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Under Skid Plate and Engine Room Under Cover Installation (Refer to GROUP 51 - Under Cover ).
  • Engine Cover Installation (Refer to GROUP 11A - Engine Assembly ).




Removal steps


1.
 Wiring harness connection


2.
 Engine oil level gauge and guide assembly


3.
 O-ring


4.
 Transmission fluid level gauge and guide assembly <A/T>


5.
 O-ring <A/T>


6.
 EGR valve and EGR pipe B fitting

>>B<<
 7.
 EGR valve gasket

>>A<<
 8.
 EGR pipe gasket


9.
 EGR valve

>>A<<
 10.
 EGR pipe gasket


11.
 EGR pipe B fitting


12.
 EGR pipe A

>>A<<
 13.
 EGR pipe gasket

>>A<<
 14.
 EGR pipe gasket


15.
 Heater piping hose connection


·
 Starter assembly (Refer to GROUP 16 - Starting System, Starter Assembly )


16.
 Water hose
<<A>>
17.
 EGR pipe B, EGR cooler and bracket assembly


18.
 EGR pipe B

>>A<<
 19.
 EGR pipe gasket


20.
 EGR cooler bracket A


21.
 EGR cooler bracket B


22.
 EGR cooler

REMOVAL SERVICE POINT

<<A>> EGR PIPE B, EGR COOLER AND BRACKET ASSEMBLY REMOVAL
1.Remove the EGR bracket mounting bolts from the wheelhouse (LH).
2.Remove the EGR pipe B, EGR cooler and bracket assembly from above the vehicle.

INSTALLATION SERVICE POINTS

>>A<< EGR PIPE GASKET INSTALLATION


The projection on the EGR pipe gasket should be position as shown.

>>B<< EGR VALVE GASKET INSTALLATION

The projection on the EGR valve gasket should be position as shown.