EGR cooler removal (4JJ3 with DPD)

1. Component views

EGR cooler

Part name

  1. Bolt
  2. Bolt
  3. Nut
  4. EGR duct
  5. EGR cooler
  6. Upper heat protector
  7. Bolt
  8. Nut
  9. EGR duct
  10. Bolt
  11. Lower heat protector
  12. Bolt
  13. Bolt

Tightening torque

1: 27 N・m { 2.8 kgf・m / 20 lb・ft }

2: 27 N・m { 2.8 kgf・m / 20 lb・ft }

3: 27 N・m { 2.8 kgf・m / 20 lb・ft }

7: 25 N・m { 2.5 kgf・m / 18 lb・ft }

8: 25 N・m { 2.5 kgf・m / 18 lb・ft }

10: 27 N・m { 2.8 kgf・m / 20 lb・ft }

12: 25 N・m { 2.5 kgf・m / 18 lb・ft }

13: 27 N・m { 2.8 kgf・m / 20 lb・ft }

2. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

Caution

  • After turning OFF the ignition switch (power mode for models with passive entry and start system), do not disconnect the battery cable within 3 minutes.
  • If the battery cable is disconnected within 3 minutes, the vehicle electronic control system may malfunction.
  • If the battery cable is disconnected, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function after connecting the battery negative terminal.

3) Raise the vehicle.

3. Underguard removal

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard removal".

4. Coolant drain

Warning

  • Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in burns caused by the release of steam or hot water.
  • When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled and slowly turn to release pressure.

1) Remove the radiator cap from the radiator.

2) Loosen the radiator drain plug, and drain the coolant into a pan.

3) Loosen the drain plug on the cylinder block, and drain the coolant to a pan.

Legend

  1. Drain plug

4) Apply LOCTITE 262 or equivalent to the threaded portion of the cylinder block side drain plug.

5) Tighten the drain plug on the cylinder block.

Tightening torque: 21.6 N・m { 2.2 kgf・m / 16 lb・ft }

6) Tighten the radiator drain plug.

5. Engine cover removal

1) Remove the engine cover from the engine.

Legend

  1. Engine cover

6. Air duct removal

1) Remove the intake air duct from the air cleaner and radiator core support.

Legend

  1. Intake air duct
  2. Clip

2) Remove the PCV hose from the cylinder head cover and air duct.

Legend

  1. PCV hose
  2. Clamp

3) Remove the air duct from the air cleaner and turbocharger.

Legend

  1. Air duct

7. Air cleaner removal

1) Disconnect the connector from the MAF and IAT sensor.

2) Remove the air cleaner from the vehicle.

Legend

  1. Air cleaner
  2. MAF and IAT sensor

8. Exhaust differential pressure sensor removal

Refer to "1.Engine 1Z.Engine Electrical Control(4JJ3 with DPD) exhaust differential pressure sensor removal".

9. Differential pressure sensor bracket removal

1) Disconnect the following sensor harnesses from the harness bracket.

  • Exhaust gas temperature sensor 1 (Front of DPD filter)
  • Exhaust gas temperature sensor 2 (Front of oxidation catalyst)
  • Heated oxygen sensor

2) Remove the differential pressure sensor bracket from the cylinder head cover.

3) Remove the harness bracket from the cylinder head cover.

Legend

  1. Harness bracket
  2. Exhaust gas temperature sensor 1 (Front of DPD filter)
  3. Differential pressure sensor bracket
  4. Heated oxygen sensor
  5. Exhaust gas temperature sensor 2 (Front of oxidation catalyst)
  6. Harness bracket

10. EGR cooler water hose disconnect

1) Disconnect the EGR cooler water feed hose from the EGR cooler.

2) Disconnect the EGR cooler water return hose from the EGR cooler.

Legend

  1. EGR cooler water return hose
  2. EGR cooler water feed hose

11. EGR cooler removal

1) Remove the upper heat protector from the EGR duct.

2) Remove the lower heat protector from the EGR duct.

3) Remove the harness bracket from the EGR duct.

4) Remove the EGR cooler and gasket from the cylinder head and exhaust manifold.

Caution

  • Do not reuse the gasket.

5) Remove the EGR duct and gasket from the EGR cooler.

Caution

  • Do not reuse the gasket.

Legend

  1. EGR duct
  2. EGR cooler
  3. EGR duct
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