EGR COOLER REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

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Replacement Part

Gasket
 
Quantity: 2
 
Location of use: EGR cooler


Fuel injector (2pin type)

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

3.  Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

4.  Remove the battery and the battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

5.  Remove the following parts as a single unit: (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Air hose
•  Air inlet pipe
•  Breather hose
•  Turbocharger air inlet hose
•  Blow-by heater

6.  Set the turbocharger air outlet pipe component aside as a single unit as shown in the figure. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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7.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 2.2].)

8.  Set the water pipe component aside as shown in the figure.

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9.  Detach the wiring harness clips shown in the figure.

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10.  Remove the EGR pipe (EGR valve side). (See EGR PIPE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

11.  Remove in the order shown in the figure.

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1
Vacuum hose No.1
(See Vacuum Hose No.1 Installation Note.)
2
Vacuum hose No.2
(See Vacuum Hose No.2 Installation Note.)
3
Water hose
4
EGR cooler insulator
5
Vacuum hose No.3
(See Vacuum Hose No.3 Removal Note.)
(See Vacuum Hose No.3 Installation Note.)
6
Vacuum pipe
(See Vacuum Pipe Installation Note.)
7
EGR cooler

12.  Install in the reverse order of removal.


Vacuum Hose No.3 Removal Note

1.  Disconnect vacuum hose No.3 on the vacuum pipe bracket side.

2.  Disconnect vacuum hose No.3, the vacuum pipe and the EGR cooler as a single unit.

3.  Remove vacuum hose No.3.


Vacuum Pipe Installation Note

Note
•  When installing the vacuum pipe, verify the tightening torque for the bolt shown in the figure because the wiring harness bracket bolt may have loosened.
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Vacuum Hose No.3 Installation Note

1.  Install vacuum hose No.3 as shown in the figure.

Vacuum pipe side

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Vacuum pipe bracket side

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Vacuum Hose No.2 Installation Note

1.  Install vacuum hose No.2 as shown in the figure.

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Vacuum Hose No.1 Installation Note

1.  Install vacuum hose No.1 as shown in the figure.

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Fuel injector (6pin type)

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

3.  Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

4.  Remove the battery and the battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

5.  Remove the following parts as a single unit: (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Air hose
•  Air inlet pipe

6.  Remove the nuts and set the turbocharger air outlet pipe component aside. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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7.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 2.2].)

8.  Set the water pipe component aside as shown in the figure.

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9.  Remove the EGR pipe (EGR valve side). (See EGR PIPE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

10.  Remove in the order shown in the figure.

11.  Install in the reverse order of removal.

12.  
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1
Water hose
(See Water Hose Installation Note.)
2
EGR cooler insulator
3
EGR cooler


Water Hose Installation Note

1.  Install the water hose as shown in the figure.

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