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Engine Emission Control > < Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube - 2.0L Duratorq-Di (Puma) Diesel (85 PS-100 PS)

Transit 2000.5 (01.2000-05.2006)

Engine Emission Control - Exhaust Gas Recirculation (EGR) Cooler—2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel Transit 2000.5 (01/2000-05/2006)
Removal and Installation

Removal

All vehicles
  1. Drain the cooling system. For additional information, refer to Section  303-03 Engine Cooling.

  1. Remove the engine oil filler pipe.

  1. Remove the intake air resonator retaining nuts.

  1. Remove the air cleaner outlet pipe and intake air resonator assembly.
Vehicles with common rail fuel injection
  1. Remove the engine upper cover.

  1. Install the engine oil filler cap to the valve cover.
All vehicles
  1. Remove the intake air resonator to turbocharger intake pipe.

  1. Disconnect the EGR valve electrical connector (if equipped).

  1. Disconnect the vacuum line from the EGR valve.

  1. Remove the EGR valve tube to EGR valve retaining bolts.
    • Discard the gasket.

  1. Disconnect the coolant hose from the EGR cooler.

  1. Remove the EGR cooler coolant hose bracket retaining bolt.

  1. Disconnect the coolant hose from the EGR cooler (catalytic converter shown removed for clarity).

  1. Remove the EGR cooler to exhaust manifold retaining bracket (catalytic converter shown removed for clarity).

  1. Remove the EGR cooler.
    • Discard the gasket.

Installation

All vehicles
  1. NOTE:
    NOTE:Install a new EGR cooler gasket.
    Install the EGR cooler.

  1. Install the EGR cooler to exhaust manifold retaining bracket (catalytic converter shown removed for clarity).

  1. Connect the coolant hose to the EGR cooler (catalytic converter shown removed for clarity).

  1. Install the EGR cooler coolant hose bracket retaining bolt.

  1. Connect the coolant hose to the EGR cooler.

  1. Loosen the EGR valve outlet tube retaining bolts.

  1. NOTE:
    NOTE:Install a new EGR valve tube to EGR valve gasket.
    Install the EGR valve tube to EGR valve bolts.

  1. Tighten the EGR valve outlet tube retaining bolts.

  1. Connect the vacuum line to the EGR valve.

  1. Connect the EGR valve electrical connector (if equipped).

  1. Install the intake air resonator to turbocharger intake pipe.
Vehicles with common rail fuel injection
  1. Remove the engine oil filler cap from the valve cover.

  1. Install the engine upper cover.
All vehicles
  1. Install the air cleaner outlet pipe and intake air resonator assembly.

  1. Install the intake air resonator retaining nuts.

  1. Install the engine oil filler pipe.
  1. Fill the cooling system. For additional information, refer to Section  303-03 Engine Cooling.

Engine Emission Control > < Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube - 2.0L Duratorq-Di (Puma) Diesel (85 PS-100 PS)