Exhaust Gas Recirculation (EGR) Cooler (115 PS)

Special tool

Clamp remover/installer 303-397 (24-003)

Withdrawal

1. Disconnect a wire of weight from the accumulator. See Section 414-01 for more information.

2. Drain the coolant from the cooling system. See Section 303-03 for more information.

3. Remove the engine top cover.



4. Remove the air baffle.



5. Disconnect the charge air cooler intake pipe from the charge air cooler.

• 1. Release the clamp.
• 2. Loosen the nut.

6. Remove the inlet pipe of the charge air cooler.

• Release the clip and disconnect the charge air cooler inlet pipe from the turbocharger.

7. Remove the charge air cooler outlet pipe.

• 1. Release the clamps.
• 2. Loosen the nut.

8.

NOTE: Mark the position of the clamp securing the EGR pipe to the EGR cooler and ensure that it is installed in exactly the same position.

Remove the clamp securing the EGR pipe to the EGR cooler

• Discard the clamp securing the EGR pipe to the EGR cooler as it is no longer needed.

9. Turn out bolts of fastening of the pipeline EGR and remove the pipeline EGR.



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 raised).



13. Turn out bolts of fastening of cooler EGR to a final collector and remove cooler EGR.

• 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 EGR cooler to exhaust manifold bolts (tighten by hand and then loosen 1.5 turns).



2.

CAUTION: Do not tighten the EGR cooler to cylinder block bolts at this stage.

Install the bolts securing the EGR cooler to the cylinder block (tighten by hand and then loosen 1.5 turns), (for clarity, the catalytic converter is shown removed and the vehicle is shown raised).



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 EGR pipe bolts (tighten by hand and then loosen 1.5 turns).



6.

CAUTION: Do not overtighten clamp.

NOTE: Install a new EGR pipe clamp to the EGR cooler.

NOTE: The EGR pipe to EGR cooler clamp must be installed in exactly the same position from which it was removed.

Install the EGR pipe clamp to the EGR cooler.



7. Tighten the EGR pipe bolts.



8. Tighten the bolts securing the EGR cooler to the exhaust manifold.



9. Tighten the bolts securing the EGR cooler to the cylinder block (for clarity, the catalytic converter is shown removed and the vehicle is shown raised).



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 engine top cover.



15. Connect a wire of weight of the accumulator. See Section 414-01 for more information.

16. Add working fluid to the cooling system. See Section 303-03 for more information.