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303-08C Engine Emission Control - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma)|Specifications > < Exhaust Gas Recirculation (EGR) Valve Outlet Tube

Mondeo 2001 (10.2000-02.2007)

Engine Emission Control - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel - Exhaust Gas Recirculation (EGR) Cooler to EGR Valve Tube Mondeo 2001 (10/2000-02/2007)
Removal and Installation

Removal

All vehicles
  1. Remove the engine cover.
  1. Remove the battery.
    For additional information, refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).

  1. Remove the battery tray.
    • Remove the clips.

  1. Detach the air cleaner housing and the air cleaner outlet pipe.
    1. Disconnect the mass air flow (MAF) sensor electrical connector.
    1. Disconnect the hoses.
    1. Lift the air cleaner housing to detach it from the retaining clips.

  1. Disconnect the clean air hose from the air cleaner housing.

  1. Remove the air cleaner housing.
Vehicles with 5-speed automatic transaxle
  1. Detach the vacuum reservoir from the retaining bracket and position it to one side.
All vehicles
  1. Detach the coolant hose from the retaining clips and position it to one side.

  1. Remove the EGR cooler to EGR valve tube retaining bolts (engine shown removed for clarity).
    • Discard the gasket.

  1. Remove the EGR cooler to EGR valve tube mounting bracket upper retaining bolt.

  1. Remove the EGR cooler to EGR valve tube retaining nuts and remove the EGR cooler to EGR valve tube.
    • Discard the gasket.

Installation

All vehicles
CAUTION:
CAUTION:The tightening sequence of the EGR cooler to EGR valve tube retaining nuts and bolts is critical. Failure to follow this instruction may result in damage to the EGR system and affect emission levels.
NOTE:
NOTE:Install new EGR cooler to EGR valve tube gaskets.
  1. NOTE:
    NOTE:Do not tighten the EGR cooler to EGR valve tube retaining nuts at this stage.
    Install the EGR cooler to EGR valve tube retaining nuts.

  1. Loosen the EGR cooler to EGR valve tube mounting bracket lower retaining bolts.

  1. NOTE:
    NOTE:Do not tighten the EGR cooler to EGR valve tube mounting bracket upper retaining bolt at this stage.
    Install the EGR cooler to EGR valve tube mounting bracket upper retaining bolt.

  1. NOTE:
    NOTE:Do not tighten the EGR cooler to EGR valve tube mounting bracket retaining bolts at this stage.
    Install the EGR cooler to EGR valve tube retaining bolts (engine shown removed for clarity).

  1. Tighten the EGR cooler to EGR valve tube retaining nuts.

  1. Tighten the EGR cooler to EGR valve tube retaining bolts (engine shown removed for clarity).

  1. Tighten the EGR cooler to EGR valve tube mounting bracket lower retaining bolts.

  1. Tighten the EGR cooler to EGR valve tube mounting bracket upper retaining bolt.
Vehicles with 5-speed automatic transaxle
  1. Attach the vacuum reservoir to the retaining bracket.
All vehicles
  1. Install the air cleaner housing.

  1. Connect the clean air hose to the air cleaner housing.

  1. Attach the air cleaner housing and the air cleaner outlet pipe.
    1. Lower the air cleaner housing to attach it to the retaining clips.
    1. Connect the hoses.
    1. Connect the MAF sensor electrical connector.

  1. Install the battery tray.
    • Install the clips.
  1. Install the battery.
    For additional information, refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).

  1. Install the engine cover.
  1. Initialize the door window motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

303-08C Engine Emission Control - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma)|Specifications > < Exhaust Gas Recirculation (EGR) Valve Outlet Tube