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

Withdrawal

All cars

1. Remove the engine top cover.



Vehicles with a 100 HP diesel engine

2. Remove the charge air cooler outlet pipe.

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

3. Disconnect the plug connector of the exhaust gas recirculation valve (EGR).



4. Disconnect the vacuum lines from the EGR valve and choke valve.




Vehicles with a 115 hp diesel engine

5. Remove the charge air cooler outlet pipe.

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

6. Disconnect the vacuum lines from the EGR valve and choke valve.



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 out of the way.



9. Remove the turbocharger. See Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G for more information.

10. Remove 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 exhaust pipe is clean and free of oil, as this reduces the friction when connecting the piping to the charge air cooler. Failure to follow this instruction may result in engine damage.

1.

NOTE: Install a new intake manifold gasket.

Reinstall the elements in reverse order.



Vehicles with a 100 HP diesel engine



Vehicles with a 115 hp diesel engine