Exhaust Gas Recirculation Cooler

Exhaust Gas Recirculation Cooler

Removing

- Drain the coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.

- Remove the upper left coolant pipe. Refer to => [ Left Upper Coolant Pipe, Vehicles Built through 05.10 ] Left Upper Coolant Pipe, Vehicles Built Through 05.10.

- Remove the right upper coolant pipe. Refer to => [ Upper Right Coolant Pipe ] Upper Right Coolant Pipe.

- Remove the oil filter housing. Refer to => [ Oil Filter Housing ] Service and Repair.

- Loosen the clamp - arrow - and remove the exhaust gas recirculation pipe - 1 -.






- Remove the bolt - 1 - and the banjo bolt - 3 - and move the turbocharger oil supply line to the side.






• Ignore - 2 -.

- Remove the bolts - 1 - and - 2 - and then remove the heat shield from the turbocharger.






- Remove the bolts - 2 - and - 3 - and remove the exhaust gas recirculation pipe.






• Ignore - 1 and 4 -.

- Remove the bolts - arrows - and remove the crankcase ventilation pipe - 1 - toward the rear.






- Remove the connector - 2 - (orange) for EGR temperature sensor (G98) from the bracket and disconnect it.






• Ignore - 1 -.

- Remove the banjo bolt - 1 - and bolt - 2 - and move the coolant line to the side.






- Disconnect the connector - 1 -.






- Carefully push the linkage - 2 - off the ball studs - arrow -.

- Remove the bolts - 3 - and then remove the intake flap motor 2 (V275) - 4 -.

- Repeat the procedure on the other side of the vehicle.

- Disconnect vacuum hose - 1 -.






- Open the clamp - 2 - and remove the coolant hose.

- Open the clamp - 3 - and remove the coolant hose.

- Remove the bolts - arrows - and then remove the exhaust gas recirculation cooler upward and off the cylinder block.

Installing

Install in reverse order of removal. Note the following:

• For the correct tightening specifications, refer to => [ Exhaust Gas Recirculation Overview ] Exhaust Gas Recirculation Overview.

• Replace seals and O-rings.

• Secure all hose connections with hose clamps appropriate for the model, refer to the Parts Catalog.

- Connect the coolant hose to the coupling. Refer to => [ Connect the Coolant Hose to the Coupling ] Radiator Overview.

- Install the intake flap motor.

- Install the coolant pipe. Refer to => [ Coolant Pipes Overview ] Coolant Pipes Overview.

- Install the turbocharger heat shield and oil supply line. Refer to => [ Turbocharger Overview ] Turbocharger Overview.

- Install the oil filter housing. Refer to => [ Oil Filter Housing ] Service and Repair.

- Remove the right upper coolant pipe. Refer to => [ Upper Right Coolant Pipe ] Upper Right Coolant Pipe.

- Remove the upper left coolant pipe. Refer to => [ Left Upper Coolant Pipe, Vehicles Built through 05.10 ] Left Upper Coolant Pipe, Vehicles Built Through 05.10.

- Fill with coolant => [ Filling ] Procedures.