Removal / installation procedure
Attention! Make sure all components are cool. Then do the job.
1. Disconnect the negative battery cable.
2. Remove decorative cover. See Section 1B, "Engine mechanical system - 2.0 Diesel".
3. Remove the hoses and ducts of the charge air system. See Section 1B, "Engine mechanical system - 2.0 Diesel".
4. Drain the engine coolant. See Section 1D1, "Engine Cooling - 2.0 Diesel".
5. Remove battery and shelf. See Section 1E1, Engine Electrical - 2.0 Diesel.
6. Remove the ECM. See «ECM controller» in this section.
7. Remove the decorative cover bracket. See «Vacuum pump» in this section.
8. Remove the engine wiring harness bracket. See «Vacuum pump» in this section.
9. Remove the exhaust pipe from the EGR cooler.
10. Disconnect the hose from the expansion tank to the water pipe.
11. Disconnect the hose from the heater to the water pipe.
12. Remove the water pipe mounting bolt from the front of the engine block.
13. Remove the EGR valve.
14. Unscrew the water pipe mounting bolts from the rear and side parts of the engine block.
15. Lower the water pipe.
16. Remove the EGR cooler.
17. Remove the EGR cooler intake pipe from the exhaust manifold.
Installation procedure
1. Install the EGR cooler intake pipe to the exhaust manifold.
2. Install the EGR cooler with the engine wiring harness bracket.
Tighten
Tighten the EGR cooler inlet pipe mounting nuts to 33 Nm (24.3 lb-ft).
Tighten the EGR cooler bolt to 20 Nm (14.8 lb-ft).
3. Install the EGR valve.
4. Screw the water pipe bolt into the engine block.
Tighten
Tighten the EGR valve nuts (to the exhaust gas recirculation cooler) up to 20 Nm (14.8 lb-ft).
Tighten the EGR valve bolts (to the EGR inlet pipe) up to 20 Nm (14.8 lb-ft).
Tighten the mounting bolt (M6) water tube up to 9 Nm (79.7 lb-in).
Tighten the mounting bolt (M8) water tube up to 20 Nm (14.8 lb-in).
5. Install the EGR cooler outlet pipe.
6. Screw the water pipe bolt into the front of the engine block.
Tighten
Tighten the bolts and nuts of the exhaust pipe of the exhaust gas recirculation cooler to 20 Nm (14.8 lb-ft).
Tighten the mounting bolt (M8) water tube up to 20 Nm (14.8 lb-in).
