RM3660EC _51 Engine / Hybrid System _080789 8ZR-FXE EMISSION CONTROL _0392058 EGR COOLER A

8ZR-FXE EMISSION CONTROL EGR COOLER REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during EGR pipe with cooler sub-assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Replacement of inverter with converter assembly	ECU configuration	-	(202304,999999,_V1,_143216,_0598316,RM100000002B3MK,)
Replacement of inverter with converter assembly	Resolver learning	· DTCs are stored · Slight vibration at a vehicle speed of 5 km/h (3 mph) or less · Shock or vibration during acceleration	(202304,999999,_51,_080773,_0600292,RM100000002BBW3,)
· Replacement of EGR valve assembly · Gas leak from exhaust system is repaired	Inspection after repair	· Poor idle, etc. · Engine start function, etc.	(202304,999999,_51,_080778,_0393982,RM100000002BDLI,)

HINT:

When the cable is disconnected / reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

Learning completes when vehicle is driven
Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
Front Camera System	Drive the vehicle straight ahead at 15 km/h (9 mph) or more for 1 second or more.	(202304,999999,_95,_139716,_0584193,RM1000000029F4C,)

PROCEDURE

Hide Display 1. PRECAUTION

NOTICE:: After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal.; Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>BEFORE DISCONNECTING BATTERY202304,202502,_V1,_143216,_0598315,RM100000002B3MI,202502,999999,_V1,_143216,_0598315,RM100000002RP07,

Hide Display G9200 2.REMOVE INVERTER WITH CONVERTER ASSEMBLY

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>8ZR-FXE INVERTER WITH CONVERTER>REMOVAL202304,999999,_51,_080773,_0392172,RM100000002B8GJ,

Hide Display 25610 3.REMOVE EGR PIPE ASSEMBLY

Click hereEngine / Hybrid System>8ZR-FXE (INTAKE / EXHAUST)>INTAKE MANIFOLD>REMOVAL202304,999999,_51,_080790,_0392072,RM100000002B0QN_01_0161,

Hide Display 16261 4.DISCONNECT WATER BY-PASS HOSE

Slide the clip and disconnect the water by-pass hose from the EGR valve assembly.

Hide Display 87245W 5.DISCONNECT INLET HEATER WATER HOSE

Slide the clip and disconnect the inlet heater water hose from the EGR pipe with cooler sub-assembly.

Hide Display 16281 6.DISCONNECT NO. 4 WATER BY-PASS HOSE

Type A:

Slide the clip and disconnect the No. 4 water by-pass hose from the EGR pipe with cooler sub-assembly.

Type B:

Slide the clip and disconnect the No. 4 water by-pass hose from the EGR pipe with cooler sub-assembly.

Hide Display 25601L 7.REMOVE EGR PIPE WITH COOLER SUB-ASSEMBLY

Disconnect the EGR valve assembly connector.

Remove the 2 nuts and disconnect the EGR pipe with cooler sub-assembly from the exhaust manifold (TWC: Front Catalyst).

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	Bolt
	Nut

Remove the bolt and 2 nuts and disconnect the EGR pipe with cooler sub-assembly with the EGR valve assembly from the cylinder head sub-assembly and camshaft housing sub-assembly.

Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the cylinder head sub-assembly and camshaft housing sub-assembly.

HINT:: If a stud bolt is deformed or the threads are damaged, replace it.

Remove the EGR pipe with cooler sub-assembly with the EGR valve assembly.

Remove the EGR cooler gasket from the EGR pipe with cooler sub-assembly.

Slide the clip and disconnect the No. 6 water by-pass hose from the EGR pipe with cooler sub-assembly.

Remove the 2 nuts and EGR pipe with cooler sub-assembly from the EGR valve assembly.

Remove the EGR valve gasket from the EGR valve assembly.

Using an E8 "TORX" socket wrench, remove the 3 stud bolts from the EGR pipe with cooler sub-assembly.

HINT:: If a stud bolt is deformed or the threads are damaged, replace it.