Special tool
 | Clamp removal/installation tool 303-397 (24-003) |
Removal
1. Disconnect the ground cable from the battery. For additional information, refer to Section 414-01.
2. Drain the coolant from the cooling system. Refer to Section 303-03 for additional information.
3. Remove the top engine cover.
4. Remove the air deflector.
5. Disconnect the charge air cooler inlet pipe from the charge air cooler.
- 1. Release the clamp.
- 2. Unscrew the nut.
6. Remove the charge air cooler inlet pipe.
- Release the clamp and disconnect the charge air cooler inlet pipe from the turbocharger.
7. Remove the charge air cooler outlet pipe.
- 1. Release the clamps.
- 2. Unscrew the nut.
8.
NOTE: Mark the position of the EGR pipe retaining clip to the EGR cooler and ensure it is installed in exactly the same position.
Remove the clamp securing the EGR pipe to the EGR cooler
- Discard the clamp that secures the EGR pipe to the EGR cooler as it is no longer needed.
9. Remove the EGR pipe mounting bolts and remove the EGR pipe.
10. Using the special tool, disconnect the EGR cooler coolant hose.
11. Using the special tool, disconnect the EGR cooler coolant hose.
12. Remove the bolts securing the EGR cooler to the cylinder block (for clarity, the catalytic converter is shown removed and the vehicle is raised).
13. Remove the bolts securing the EGR cooler to the exhaust manifold and remove the EGR cooler.
- Discard the gasket between the EGR cooler and the exhaust manifold as it is no longer needed.
Installation
1.
CAUTION: Do not tighten the EGR cooler to exhaust manifold bolts at this stage.
NOTE: Install a new gasket between the EGR cooler and the exhaust manifold.
Install the EGR cooler to exhaust manifold mounting bolts (hand tighten and then loosen 1.5 turns).
2.
CAUTION: Do not tighten the EGR cooler to cylinder block bolts at this stage.
Install the EGR cooler to cylinder block mounting bolts (hand tighten and then loosen 1.5 turns) (catalytic converter shown removed and vehicle shown raised for clarity).
3. Using the special tool, connect the EGR cooler coolant hose.
4. Using the special tool, connect the EGR cooler coolant hose.
5.
CAUTION: Do not tighten the EGR pipe mounting bolts at this stage.
Install the EGR pipe mounting bolts (hand tighten and then loosen 1.5 turns).
6.
CAUTION: Do not overtighten the clamp.
NOTE: Install a new EGR line to EGR cooler retaining clip.
NOTE: The EGR pipe to EGR cooler retaining clip must be installed in the exact same position from which it was removed.
Install the EGR pipe retaining clamp to the EGR cooler.
7. Tighten the EGR pipe bolts.
8. Tighten the EGR cooler mount bolts to the exhaust manifold.
9. Tighten the EGR cooler to engine block mounting bolts (catalytic converter shown removed and vehicle shown raised for clarity).
10. Install the charge air cooler outlet pipe.
- 1. Tighten the clamps.
- 2. Screw on the nut.
11. Connect the charge air cooler inlet pipe to the turbocharger.
12. Install the charge air cooler inlet pipe.
- 1. Tighten the clamp.
- 2. Install the nut.
13. Install the air deflector.
14. Install the top engine cover.
15. Connect the battery ground cable. Refer to Section 414-01 for additional information.
16. Add coolant to the cooling system. Refer to Section 303-03 for additional information.
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