EGR Valve: Service and Repair

Remove/Install Exhaust Gas Recirculation Valve

Shown On Engine 112:

Shown On Engine 112:

Remove/Install

DANGER:
- Risk of injury to skin and eyes from handling hot or glowing objects.
- Wear safety gloves, protective clothing and safety glasses, if necessary.

1.1 Unclip cover at face end of engine
1.2 Remove the cylinder head cover trim or the air cleaner housing

NOTE:
- Take Out the cylinder head cover trim or the air cleaner housing from the cylinder head covers vertically in the upward direction.
- Installation: Moisten slightly with sliding compound the retaining rubbers on the cylinder head covers and the sealing ring of the hot film mass air flow sensor in the air cleaner housing.
- Liquid lubricant (Naphtolen H)

2.1 Remove hot film mass air flow sensor together with air intake pipe
3.1 Dismantle oil dipstick guide tube (1) and turn it to the side

NOTE: Installation: ensure sealing ring of dipstick guide tube (1) is correctly seated in top part of oil pan.

3.2 Detach the oil dipstick guide tube (1) from the bracket at the exhaust gas recirculation valve (89) and press it to the side
4.1 Dismantle retaining clip from oil dipstick guide tube (1)
5.1 Loosen the fuel distributor rail (2) on the right side and move it to the side
6.1 Detach coupling (3) from injection valve
7 Unplug connector on EGR vacuum transducer (Y31/1).
8 Detach the vacuum line (b) from the exhaust gas recirculation valve (89) to the exhaust gas recirculation pressure transducer (Y31/1)
9 Unscrew acorn nut (89/3) on exhaust gas recirculation valve (89)
- See Specifications below.

10.1 Dismount EGR line (89/1)from intake manifold (19)
- See Specifications below.

11 Unscrew the exhaust gas recirculation valve (89) from the cylinder head
- See Specifications below.

12 Remove exhaust gas recirculation valve (89)

CAUTION: Installation: Install new gaskets. Pay attention to length and routing of vacuum pipe from intake pipe (19) to EGR transducer (Y31/1). Incorrect routing may cause throttle lever to jam

13 Install in the reverse order

Specifications

Exhaust Gas Recirculation: