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Positive Crankcase Ventilation (PCV) Valve > < Exhaust Gas Recirculation (EGR) Valve

Focus 2004.75 (07.2004-)

Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel - Exhaust Gas Recirculation (EGR) Cooler Focus 2004.75 (07/2004-)
Removal and Installation

Special Tool(s)

Remover/Installer, Cooling Hose Clamp

303-397 (24-003)
General Equipment
Trolley jack
  1. Drain the cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding - 2.0L (303-03E Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel, General Procedures).
  1. NOTE:
    NOTE:Make sure that the windshield wiper motor is in the park position.
    Disconnect the battery ground cable.
    For additional information, refer to: Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures).

  1. Remove the engine upper cover.

  1. Detach the brake fluid reservoir from the bulkhead extension panel.

  1. Remove the windshield wiper arms.

  1. Remove the cowl panel.
    1. Detach the cowl panel from the retaining clips.
    1. Remove the cowl panel by detaching it from the windshield glass lower weatherstrip.

  1. Remove the bulkhead extension panel.
    1. Remove the bulkhead extension panel retaining screws.
    1. Detach the bulkhead extension panel from the retaining clips.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Remove the engine support insulator retaining bolt.
  1. Lower the vehicle.

  1. Detach the coolant expansion tank and secure it to one side.
  1. CAUTION:
    CAUTION:Insert a wooden block between the oil pan and the trolley jack.
    Position the trolley jack with the wooden block under the oil pan and raise so that the front engine mount is free from load.

  1. Remove the engine mount to chassis retaining bolts.
  1. CAUTION:
    CAUTION:Take care not to crush or put excessive force on the components between the engine and the radiator.
    With the aid of another technician slide the engine towards the radiator.

15. Remove the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Turbocharger intake pipe positive crankcase ventilation (PCV) hose
See Removal Detail
2
-
Heater core to EGR cooler coolant hose quick release coupling
See Removal Detail
3
-
Coolant bypass pipe to EGR cooler coolant hose retaining clamp
See Removal Detail
4
-
Coolant bypass pipe to EGR cooler coolant hose
5
-
EGR cooler tube heat shield
6
-
EGR cooler retaining clamp
See Removal Detail
See Installation Detail
7
-
EGR cooler tube retaining nuts
See Installation Detail
8
-
EGR cooler tube
9
-
EGR cooler tube gasket
10
-
EGR cooler support bracket retaining nut
See Installation Detail
11
-
EGR cooler retaining bolts
See Installation Detail
12
-
EGR cooler

16. To install, reverse the removal procedure.

  1. Vehicles with global closing, initialize the door window motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

Removal Details

Item 1 : Turbocharger intake pipe positive crankcase ventilation (PCV) hose
  1. Detach the PCV hose from the turbocharger intake pipe.

Item 2 : Heater core to EGR cooler coolant hose quick release coupling
  1. Disconnect the heater core to EGR cooler coolant hose quick release connector.
    • Remove the retaining clip.

Item 3 : Coolant bypass pipe to EGR cooler coolant hose retaining clamp
  1. Using the special tool, detach the coolant bypass pipe to EGR cooler coolant hose retaining clamp.

Item 6 : EGR cooler retaining clamp
  1. Make a note of the position of the EGR cooler retaining clamp before removal.

Installation Details

Item 11 : EGR cooler retaining bolts

  1. NOTE:
    NOTE:Do not tighten the EGR cooler retaining bolts at this stage.
    Install the EGR cooler retaining bolts.

Item 10 : EGR cooler support bracket retaining nut

  1. NOTE:
    NOTE:Do not tighten the EGR cooler support bracket retaining nut at this stage.
    Install the EGR cooler support bracket retaining nut.

Item 7 : EGR cooler tube retaining nuts

  1. NOTE:
    NOTE:Do not tighten the EGR cooler tube retaining nuts at this stage.
    Install the EGR cooler tube retaining nuts.

Item 6 : EGR cooler retaining clamp
  1. NOTE:
    NOTE:A new EGR cooler retaining clamp must be installed in the same position as removed.
    Install a new EGR cooler retaining clamp.

  1. Tighten the EGR cooler components in the order indicated.
    1. EGR cooler retaining bolts.
    1. EGR cooler tube retaining nuts.
    1. EGR cooler retaining nut.

Positive Crankcase Ventilation (PCV) Valve > < Exhaust Gas Recirculation (EGR) Valve