EGR Cooler: Service and Repair

Bypass Flap with EGR Cooler

- Drain the coolant. Refer to => [ Draining and Filling ] Draining and Filling.

- Disconnect all necessary connectors on the engine wiring harness above the engine and lay it aside.

- Remove the vacuum pipe - A - including it brackets on the intake manifold - arrows -.






- Remove the engine cover pins - arrow - on both intake manifolds.






- Remove the bolts - arrows -, open the clamps and remove the coolant hoses - 1 and 2 -.






- Remove the coolant pipe bolt behind the bypass flap - arrow -.

- Remove the coolant hose - 2 - and move the coolant pipe - 1 - to the rear.






- Remove the Exhaust Gas Recirculation (EGR) connecting pipe bolts - arrow - and remove the intake connection with the intake manifold flap motor - A - and EGR valve - B - from both intake manifolds.






- Remove the bolts on the EGR connecting pipes in the cylinder head area and remove their brackets => [ (Item 9) Bracket ] EGR System.

- Loosen the bypass flap bolt - arrow - completely, raise the back of the flap slightly and remove the bolt.






- Remove the front of the bypass flap upward from the retainers.

- Guide the bypass flap with the EGR pipes out between the engine bulkhead and intake manifolds.

Installing

Installation is performed in reverse order. When doing this note the following:

- Replace all seals and O-rings.

- Reconnect all lines, hoses and connections that were disconnected for the removal sequence.

- Replace the bolt for the vacuum pipe bolt on the cylinder bank 2 intake manifold with a bolt of the same size and strength category.

- Fill with coolant. Refer to => [ Draining and Filling ] Draining and Filling.