Engine Emission Control - 1.8L Diesel - Exhaust Gas Recirculation (EGR) Valve—1.8L Diesel (75 PS/90 PS)
Focus 1999 (08/1998-12/2004)
Removal and Installation
Removal
NOTE:Make a note of the orientation of the retaining clamps.
Remove the charge air cooler outlet pipe.
Loosen the retaining clamps.
Remove the nuts.
Discard the retaining clamps.
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.
Disconnect the exhaust gas recirculation (EGR) valve electrical connector and vacuum tubes.
Detach the power steering pipe bracket.
Remove one bolt.
Detach the power steering pipe bracket.
Remove one bolt.
Remove the turbocharger. For additional information, refer to: Turbocharger - 1.8L Diesel (75 PS/90 PS) (303-04D Fuel Charging and Controls - Turbocharger, Removal and Installation).
Remove the inlet manifold and EGR valve.
Remove and discard the intake manifold gasket.
Installation
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: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.
NOTE:Install a new intake manifold gasket.
To install, reverse the removal procedure.
NOTE:Install a new retaining clamp.
NOTE:Make sure the retaining clamps are in the same orientation as when removed.
Install a new charge air cooler pipe to intake manifold hose and retaining clamps.
NOTE:Install a new retaining clamp.
NOTE:Make sure the retaining clamps are in the same orientation as when removed.
