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

Withdrawal

1. Disconnect the charge air cooler intake pipe.

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

2. Remove the charge air cooler inlet pipe.



3. Remove the charge air cooler outlet pipe.

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

4.

NOTE: Mark the position of the clip to ensure it is in exactly the same position when installing.

Remove the EGR pipe clamp (EGR).



5. Loosen the EGR pipe bolts.



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

7. Disconnect the EGR cooler upper coolant hose.



8. Raise and support the vehicle. See Section 100-02 for more information.


9. Remove engine protection.



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



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



12. Lower the car.

13.

NOTE: Mark the position of the clip to ensure it is in exactly the same position when installing. The clamp loop must be covered by the EGR pipe when viewed from the top of the engine. This is necessary in order to give access to the catalytic converter nuts.

Remove the EGR cooler clip 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 clip and EGR cooler gasket.

NOTE: Do not tighten bolts at this stage.

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



2.

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

NOTE: Be sure to install the clip in the same position it was in before removal.

Install a new EGR cooler clip.



3. Tighten the EGR cooler bolts.



4. Install the lower EGR cooler coolant hose.



5. Install motor protection.



6. Install the upper EGR cooler coolant hose.



7.

CAUTION: Do not overtighten clamp.

Install the EGR pipe clamp.



8. Tighten the EGR pipe bolts.



9.

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.

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 the inside of the charge air cooler intake pipe end 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.

Connect the intake pipe to the charge air cooler.

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

12. Fill in cooling liquid in the cooling system. See Section 303-03 for more information.