1. 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.
2. Underguard removal
3. Engine oil drain
1) Remove the drain plug from the oil pan, and drain the engine oil to a pan.
2) Install the drain plug to the oil pan.
Caution
- Do not reuse the gasket.
- Wipe off any oil attached to the drain plug hole.
- Do not forget to tighten the drain plug.
Tightening torque: 83 N・m { 8.5 kgf・m / 61 lb・ft }
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
- Drain plug
4) Apply LOCTITE 262 or equivalent to the threaded portion of the 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
- Engine cover
6. Air intake hose removal
1) Remove the air intake hose from the intake air duct and intercooler.
Legend
- Intercooler
- Air intake hose
- Intake air duct
- Clamp
7. Intake air duct removal
1) Disconnect the connector from the boost pressure and CAC temperature sensor.
2) Remove the intake air duct from the intake throttle valve.
8. Oil level gauge guide tube removal
1) Remove the oil level gauge from the oil level gauge guide tube.
2) Remove the oil level gauge guide tube from the crankcase.
9. Water pipe removal
1. Except for Euro4 specifications
1) Disconnect the vacuum hose from the vacuum pipe.
2) Remove the vacuum pipe from the air duct bracket.
Euro2 specifications
Legend
- Vacuum pipe
- Vacuum hose
- Bracket
Except for Euro2 specifications
Legend
- Vacuum hose
- Vacuum pipe
- Bracket
- Relief valve control solenoid valve
- Relief valve control solenoid valve bracket
3) Remove the water hose from the water pipe.
Manual transmission models
Automatic transmission models
4) Remove the water pipe from the air duct bracket.
5) Remove the pipe clip from the water pipe.
6) Remove the water pipe from the inlet cover.
Manual transmission models
Automatic transmission models
10. EGR cooler water hose disconnect
1. Euro4 specifications
1) Disconnect the EGR cooler water feed hose from the EGR cooler.
2) Disconnect the EGR cooler water return hose from the EGR cooler.
Manual transmission models
Legend
- EGR cooler water return hose
- EGR cooler water feed hose
Automatic transmission models
Legend
- EGR cooler water return hose
- EGR cooler water feed hose
3) Disconnect the EGR cooler water hose from EGR cooler water pipe A.
4) Remove EGR cooler water pipe A from the inlet cover.
Manual transmission models
Legend
- EGR cooler water pipe A
- EGR cooler water hose
- EGR cooler water pipe B
Automatic transmission models
Legend
- EGR cooler water pipe A
- EGR cooler water hose
- Water pipe
11. Fuel leak-off pipe removal
1) Disconnect the fuel leak-off hose from the fuel leak-off pipe.
2) Remove the fuel leak-off pipe from the common rail (fuel rail) and flywheel housing.
Caution
- Cover the exposed section to prevent the intrusion of foreign material.
Legend
- Fuel leak-off pipe
12. Fuel feed pipe removal
1) Remove the clip from the fuel feed pipe.
2) Remove the fuel feed pipe from the fuel supply pump and common rail (fuel rail).
Caution
- Do not reuse the fuel feed pipe.
- Cover the exposed section to prevent the intrusion of foreign material.
Legend
- Fuel feed pipe
13. CMP sensor removal
1) Remove the fuel pipe bracket from the cylinder head.
Legend
- Fuel pipe bracket
- CMP sensor
- Cylinder head
2) Disconnect the connector from the CMP sensor.
3) Remove the CMP sensor from the cylinder head.
Legend
- O-ring
- CMP sensor