Method B, Motronic 4.3, Non-Turbo Auto US/CDN Only

DELETING THE EGR-SYSTEM

NOTE: Method "A" should be performed prior to this method if the vehicle is older than M/Y 96 (production date 03/96).





Parts Required:
- EGR-kit 272250-2





- Engine Control Module (ECM) see table





- Vacuum and emission labels see table

B1 Remove:
- Battery negative lead
- Throttle pulley cover.





Removing Engine Coolant Fan Shroud
B2 Remove:
- Air intake scoop in front and inlet hose to the air cleaner
- Air duct to the control module box
- 4 screws on engine coolant fan shroud.





B3 Remove:
- EVAP valve including hoses from fan shroud (if applicable)
- EGR controller from upper air guide and disconnect EGR controller connector.





B4 Remove:
- EGR controller with hoses and discard.

Install:
- Rubber plug on multi nipple.





B5 Remove:
- Disconnect the two connectors (A) to the engine coolant fan (FC)
- Free cable harnesses from fan shroud.
Place the air guide with the relays on top of the engine.


Remove:
- Engine coolant fan (FC) by pulling engine coolant fan (FC) and shroud upwards.
- Cover the radiator with protective panel P/N 999 5474 or equivalent.





B6 Remove:
- Inlet hose between air cleaner and the hose on throttle body
- Idle air control valve hose and hose for crankcase ventilation, from the inlet hose
- Idle Air Control (IAC) valve and Throttle Position (TP) sensor connectors.





Deleting EGR-system
B7 Remove:
- EGR pipe from exhaust manifold
- Nipple from exhaust manifold.

Install:
- Plug and nut on exhaust manifold. Torque 60 Nm (44 ft.lb).





B8 Remove:
- EGR temperature sensor wire from connector
- EGR valve pipe coupling
- EGR valve and pipe and discard.
Clean gasket face on manifold.

Install:
- New cover plate and gasket using new bolts on intake manifold. Torque 10 Nm (7.5 ft.lb).
- Plug on the EGR temperature sensor wire connector.

Re-installing Parts

B9 Install:
- Inlet hose between air cleaner and Throttle Body (TB)
- Idle air control valve hose and hose for crankcase ventilation on the inlet hose
- Idle Air Control (IAC) valve and Throttle Position (TP) sensor connectors.

B10 Remove:
- Protective panel from the radiator.





Install:
- Engine coolant fan (FC) and shroud
- The two lower engine coolant fan screws loosely.
Fix the cable with the tie strap and clip.
Connect the two connectors to engine coolant fan (FC).





B11 Install:
- EVAP hose with clips to the engine coolant fan (FC)
- EVAP valve.





B12 Install:
- Two spacer washers on top
- Upper air guide
- Two upper screws on engine coolant fan (FC) and tighten all four
- Air intake and inlet hose to the Air Cleaner (ACL)
- Throttle pulley cover.





B13 Install:
- Plug and clip as shown and park the EGR controller wire in the plug.





B14 Replace:
- Engine Control Module (ECM).

NOTE: Apply one of the enclosed TMA-adhesive labels on the side of the ECM. Do not forget to enter the return into the Pans Volvo Vision core return screen (option 2, TMA testing returns) and enclose packing list.
For US, pack the ECM in a box, labelled with the second TMA-label, and send it to TMA, Rockleigh, for re-programming.
For Canada, the ECM should be handled the normal way, i.e. shipped to TMA, Toronto. This means that the second label from the kit shouldn't be used.





B15 Clean surfaces on the current vacuum hose and emission labels

Install:
- Vacuum hose label "A" on top of the old one.
- Emission label "B" on top of the old one.

B16 Install:
- Battery negative lead.
- Reset radio anti-theft code.

Perform test drive:
- Check that there are no DTC's stored in the system after the test drive.