Modulator - EGR (page 2 of 2)

10. Remove EGR valve assembly.

Valve - EGR - Pre EU3 models 11. Remove clip and remove pipe from EGR valve.

Refit

$% 17.45.01

On all vehicles up to VIN number 1A736339, the EGR pipe assembly must be replaced every time the system is disturbed.

Remove

1. Release turnbuckles and remove battery cover.
2. Disconnect battery earth lead.
3. Remove 3 bolts and remove engine acoustic cover.
4. Remove cooling fan coupling. COOLING SYSTEM - Td5, REPAIRS, Fan - viscous.

10. Fit cooling fan coupling.
11. Connect battery earth lead.
12. Fit battery cover and secure the fixings.
5. Disconnect vacuum hose(s) from EGR valve.
6. Loosen clip and release air intake from EGR valve.
7. Remove 4 bolts, release EGR valve from inlet manifold and discard gasket.
8. Remove 2 bolts and release EGR valve clip from cylinder head.

9. Remove and discard 2 bolts securing EGR valve pipe to exhaust manifold.
1. Clean EGR valve and mating face on pipe.
2. Position pipe to EGR valve and fit retaining clip. Fit bolt but do not tighten at this stage.
3. Position EGR valve assembly, locate pipe flange to exhaust manifold, fit new bolts but do not tighten at this stage.
4. Clean inlet manifold and EGR valve mating faces.
5. Using new gasket, position EGR valve to inlet manifold fit bolts and tighten to 10 Nm (7 lbf.ft).
6. Align EGR pipe clip to cylinder head, fit bolts but do not tighten at this stage.
7. Tighten EGR pipe bolts to correct torque in following sequence: l EGR pipe retaining clip bolt 6 Nm (4.5 lbf.ft) l EGR pipe clip to cylinder head bolts 10 Nm (7 lbf.ft) l EGR pipe flange to exhaust manifold bolts 10 Nm (7 lbf.ft)
8. Position air intake hose and tighten clip.
9. Connect vacuum hoses to EGR valve.

COOLING SYSTEM - Td5, REPAIRS, Fan - viscous.