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Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube > < Exhaust Gas Recirculation (EGR) Valve - 1.8L Diesel (75 PS-90 PS)

Focus 1999 (08.1998-12.2004)

Engine Emission Control - 1.8L Diesel - Exhaust Gas Recirculation (EGR) Valve—1.8L Diesel, Vehicles With: Common Rail Fuel Injection Focus 1999 (08/1998-12/2004)
Removal and Installation

Removal

All vehicles
  1. Remove the engine upper cover.
Vehicles with 100 PS diesel engine
  1. NOTE:
    NOTE:Make a note of the orientation of the retaining clamps.
    Remove the charge air cooler outlet pipe.
    1. Loosen the retaining clamps.
    1. Remove the nuts.
    • Disconnect the vacuum line from the charge air cooler outlet pipe.
    • Discard the retaining clamps.

  1. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.

  1. Disconnect the vacuum lines from the EGR valve and the air shutoff throttle.
Vehicles with 115 PS diesel engine
  1. NOTE:
    NOTE:Make a note of the orientation of the retaining clamps.
    Remove the charge air cooler outlet pipe.
    1. Loosen the retaining clamps.
    1. Remove the nuts.
    • Discard the retaining clamps.

  1. Disconnect the vacuum lines from the EGR valve and the air shutoff throttle.
All vehicles
  1. NOTE:
    NOTE:Make a note of the orientation of the retaining clamp.
    Remove the charge air cooler outlet pipe to intake manifold hose.
    • Discard the pipe and the retaining clamps.

  1. Disconnect the electronic vacuum regulating valves electrical connectors.

  1. Detach the electronic vacuum regulating valves support bracket and secure it to one side.
  1. Remove the turbocharger.
    For additional information, refer to: Turbocharger - 1.8L Diesel, Vehicles With: Common Rail Fuel Injection (303-04D Fuel Charging and Controls - Turbocharger, Removal and Installation).

  1. Remove the intake manifold and EGR valve.
    • Discard the gasket.

Installation

All vehicles
CAUTION:
CAUTION:Make sure that the inside of the charge air cooler outlet pipe end is clean and free from any oil residue as this will reduce the installation grip of the pipe to the charge air cooler. Failure to follow this instruction may result in damage to the engine.
CAUTION:
CAUTION:Make sure that a new charge air cooler outlet pipe to intake manifold hose and all new charge air cooler hose retaining clamps are installed. Failure to follow this instruction may result in damage to the engine.
  1. NOTE:
    NOTE:Install a new intake manifold gasket.
    To install, reverse the removal procedure.

  1. NOTE:
    NOTE:Make sure the retaining clamps are in the same orientation as when removed.
    Install a new charge air cooler outlet pipe to intake manifold hose and retaining clamps.
Vehicles with 100 PS diesel engine
  1. NOTE:
    NOTE:Make sure the retaining clamps are in the same orientation as when removed.
    Install the charge air cooler outlet pipe.
    1. Tighten the retaining clamps.
    1. Install the nuts.
    • Connect the vacuum line to the charge air cooler outlet pipe.
Vehicles with 115 PS diesel engine
  1. NOTE:
    NOTE:Make sure the retaining clamps are in the same orientation as when removed.
    Install the charge air cooler outlet pipe.
    1. Tighten the retaining clamps.
    1. Install the nuts.

Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube > < Exhaust Gas Recirculation (EGR) Valve - 1.8L Diesel (75 PS-90 PS)