Exhaust Gas Recirculation (EGR) Valve (1.8L Diesel Injection)

Removal

All cars

1. Remove the top engine cover.



Cars with diesel engine 100 hp.

2. Remove the charge air cooler outlet pipe.

• 1. Release the clamps.
• 2. Unscrew the nut.
• Disconnect the vacuum line from the charge air cooler outlet pipe.

3. Disconnect the EGR valve connector.



4. Disconnect the vacuum lines from the EGR valve and the air throttle body.




Cars with 115 hp diesel engine.

5. Remove the charge air cooler outlet pipe.

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

6. Disconnect the vacuum lines from the EGR valve and the air throttle body.



All cars

7. Disconnect the plug connectors of the electronic vacuum control valves.




8. Disconnect the electronic vacuum control valve support bracket and secure it to the side.



9. Remove the turbocharger. For additional information, refer to Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G.

10. Remove the intake manifold and EGR valve. Discard the gasket as it is no longer needed.

Installation

All cars

CAUTION: Make sure the inside of the end of the charge air cooler outlet 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.

1.

NOTE: Install a new intake manifold gasket.

Install the elements back in place in reverse order.



Cars with diesel engine 100 hp.



Cars with 115 hp diesel engine.