Exhaust Gas Recirculation (EGR) Cooler (75 PS/90 PS)

Removal

1. Disconnect the charge air cooler inlet pipe.

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

2. Remove the charge air cooler inlet pipe.



3. Remove the charge air cooler outlet pipe.

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

4.

NOTE: Mark the position of the clamp so that it can be installed in exactly the same position during installation.

Remove the exhaust gas recirculation (EGR) line clamp.



5. Loosen the EGR pipe bolts.



6. Drain the coolant from the cooling system. Refer to Section 303-03 for additional information.

7. Disconnect the upper EGR cooler coolant hose.



8. Raise and support the vehicle. Refer to Section 100-02 for additional information.


9. Remove the engine protection.



10. Disconnect the lower EGR cooler coolant hose (catalytic converter not shown).



11. Remove the EGR cooler bolts (the catalytic converter is not shown).



12. Lower the vehicle.

13.

NOTE: Mark the position of the clamp so that it is installed in exactly the same position. The loop of the clamp must be covered by the EGR pipe when viewed from the top of the engine. This is necessary to allow access to the catalytic converter nuts.

Remove the EGR cooler clamp and discard it as no longer needed.



14. Remove the EGR cooler.



15. Remove the EGR cooler gasket and discard it as no longer needed.

Installation

1.

NOTE: Install a new EGR cooler clamp and EGR cooler gasket.

NOTE: Do not tighten the bolts at this stage.

Install the EGR cooler bolts (hand tighten and then loosen 1.5 turns).



2.

CAUTION: To ensure uniform compression of the EGR pipe gasket when installing the pipe clamp, pipe movement must not be restricted by the pipe bolts.

NOTE: Ensure that the clamp is installed in the same position as it was before removal.

Install the new EGR cooler clamp.



3. Tighten the EGR cooler bolts.



4. Install the lower EGR cooler coolant hose.



5. Install the engine protection.



6. Install the EGR cooler upper coolant hose.



7.

CAUTION: Do not overtighten the clamp.

Install the EGR pipe clamp.



8. Tighten the EGR pipe bolts.



9.

CAUTION: Make sure the inside of the charge air cooler outlet pipe end is clean and free of oil, as this will reduce adhesion when connecting the pipe to the charge air cooler. Failure to follow this instruction may result in engine damage.

Install the charge air cooler outlet pipe.

• 1. Tighten the clamps.
• 2. Tighten the nut.

10. Install the charge air cooler inlet pipe.



11.

CAUTION: Make sure that the inside of the end of the charge air cooler intake pipe is clean and free of oil, as this will reduce adhesion when connecting the pipe to the charge air cooler. Failure to follow this instruction may result in engine damage.

Connect the intake manifold to the charge air cooler.

• 1. Tighten the clamp.
• 2. Tighten the nut.

12. Fill the cooling system with coolant. Refer to Section 303-03 for additional information.