Exhaust Gas Recirculation Valve, Replace
J982500
Remove
1. Disconnect battery negative lead
2. Disconnect hose (1) from oil filler on air cleaner assembly, then move to one side • Release clip (2)
S 0012751
1 2
3. Disconnect hose (2) from mass air flow meter (1) • Release clip
4. Disconnect harness connector (3) from mass air flow meter
S 0012749
1
2
3
5. Remove air intake duct (1) from air cleaner assembly (2) and front panel • Release 2x clip
Page 1 of 20510984Exhaust Gas Recirculation Valve, Replace
02/01/2014file://C:\Program Files\cosids\DATA\TMP\00510984.rtf.html
S 0012752
1
2
6. Remove air cleaner assembly from support frame • Pull off from 4x locating peg (1)
S 0012753
11
7. Release charge pressure sensor and base adapter (2) from support frame • Pull off
8. Release harness for charge pressure sensor from support frame (1) • Release clip (3)
Page 2 of 20510984Exhaust Gas Recirculation Valve, Replace
02/01/2014file://C:\Program Files\cosids\DATA\TMP\00510984.rtf.html
S 0012916
1 2
3
9. Release fuel pipe (2) from support frame (1) • Release 2x clip
S 0012919
1 2
10. Release harness (1) for mass air flow meter from support frame (2) • Release clip (3)
Page 3 of 20510984Exhaust Gas Recirculation Valve, Replace
02/01/2014file://C:\Program Files\cosids\DATA\TMP\00510984.rtf.html
S 0012861
1
2
3
11. Release harness for coolant heater assembly (if installed) from support frame • Release clip (2)
12. Release bracket with coolant heater assembly (1) (if installed) from support frame • Remove bolt (3)
S 0012860
1
2
3
Page 4 of 20510984Exhaust Gas Recirculation Valve, Replace
02/01/2014file://C:\Program Files\cosids\DATA\TMP\00510984.rtf.html
S 0012862
2
3
1
13. Remove support frame (1) from engine compartment • Remove 2x nut (2), 2x bolt (3)
14. Remove intercooler outlet pipe from engine compartment • Release 3x clip
• Disconnect harness connector
S 0013100
Important: When removing duct assembly, release securing clips last. 15. Remove duct assembly (2) from intercooler
and turbocharger • Remove bolt (3)
• Release 2x clip (1)
Page 5 of 20510984Exhaust Gas Recirculation Valve, Replace
02/01/2014file://C:\Program Files\cosids\DATA\TMP\00510984.rtf.html
16. Remove O ring from duct assembly
17. Remove radiator grille from vehicle • Remove 5x bolt (1)
• Release from 10x retaining clip
Page 6 of 20510984Exhaust Gas Recirculation Valve, Replace
02/01/2014file://C:\Program Files\cosids\DATA\TMP\00510984.rtf.html
18. Remove intercooler from upper front panel • Remove 2x bolt (1)
• Release 2x locating pin of intercooler from 2x rubber guide – Pull upwards
Page 7 of 20510984Exhaust Gas Recirculation Valve, Replace
02/01/2014file://C:\Program Files\cosids\DATA\TMP\00510984.rtf.html
19. Remove dipstick with guide tube assembly from engine • Remove bolt (1)
• Remove O ring
• Install new blanking plug
Page 8 of 20510984Exhaust Gas Recirculation Valve, Replace
02/01/2014file://C:\Program Files\cosids\DATA\TMP\00510984.rtf.html
S 0013433
1
20. Remove throttle valve assembly from engine • Disconnect harness connector
• Release fuel pipe from clip
• Remove 6x bolt
• Remove gasket – Release 2x clip
S 0013434
21. Remove exhaust gas recirculation (EGR) pipe from cooler and control valve • Remove 4x bolt, 2x gasket
Page 9 of 20510984Exhaust Gas Recirculation Valve, Replace
02/01/2014file://C:\Program Files\cosids\DATA\TMP\00510984.rtf.html
Install
S 0013361
22. Remove intercooler outlet hose support bracket from intake manifold • Remove 2x bolt (4)
23. Remove EGR valve (1) from engine • Disconnect harness connector (2)
• Remove 3x bolt (3), gasket
S 0013435
2
1
4
3
24. Install new EGR valve (1) to engine • Clean mating surfaces
• Install new gasket, 3x bolt (3) 21 Nm
• Connect harness connector (2)
25. Install intercooler outlet hose support bracket to intake manifold • Install 2x bolt
Page 10 of 20510984Exhaust Gas Recirculation Valve, Replace
02/01/2014file://C:\Program Files\cosids\DATA\TMP\00510984.rtf.html
S 0013435
2
1
4
3
26. Install EGR pipe to cooler and control valve • Clean mating surfaces
• Install 2x new gasket
• Install 4x bolt 25 Nm
S 0013361
27. Install throttle valve assembly to engine • Clean mating surfaces
• Install new gasket – Secure 2x clip
• Install 6x bolt 12 Nm
• Secure fuel pipe to clip
• Connect harness connector
Page 11 of 20510984Exhaust Gas Recirculation Valve, Replace
02/01/2014file://C:\Program Files\cosids\DATA\TMP\00510984.rtf.html
S 0013434
28. Install dipstick with guide tube assembly to engine • Remove blanking plug
• Install new O ring
• Install bolt (1) 10 Nm
S 0013433
1
29. Install intercooler to upper front panel • Secure 2x locating pin of intercooler to
2x rubber guide – Push downwards
• Install 2x bolt (1) 8 Nm
Page 12 of 20510984Exhaust Gas Recirculation Valve, Replace
02/01/2014file://C:\Program Files\cosids\DATA\TMP\00510984.rtf.html
30. Install radiator grille to vehicle • Secure to 10x retaining clip
• Install 5x bolt (1) 4 Nm
Page 13 of 20510984Exhaust Gas Recirculation Valve, Replace
02/01/2014file://C:\Program Files\cosids\DATA\TMP\00510984.rtf.html
Important: Ensure correct assembly sequence is observed and duct assembly is positioned in correct axis, and to correct side of support bracket. 31. Install duct assembly (2) to engine
compartment • Install new O ring to intercooler pipe
– Apply suitable lubricant to O ring, then position to intercooler pipe
• Position duct to turbocharger and intercooler in correct axis with no twisting or levering movements
• Install bolt (3) – Observe position of duct to
support bracket
• Secure 2x clip (1) – Clip to be secured last in
assembly sequence
Page 14 of 20510984Exhaust Gas Recirculation Valve, Replace
02/01/2014file://C:\Program Files\cosids\DATA\TMP\00510984.rtf.html
32. Install intercooler outlet pipe to engine compartment • Secure 3x clip
• Connect harness connector
Page 15 of 20510984Exhaust Gas Recirculation Valve, Replace
02/01/2014file://C:\Program Files\cosids\DATA\TMP\00510984.rtf.html
S 0013100
S 0012862
2
3
1
33. Install air cleaner assembly support frame (1) to engine compartment • Install 2x bolt (3), 2x nut (2)
34. Secure bracket with coolant heater assembly (1) (if installed) to support frame • Install bolt (3)
35. Secure harness for coolant heater assembly (if installed) to support frame • Secure clip (2)
Page 16 of 20510984Exhaust Gas Recirculation Valve, Replace
02/01/2014file://C:\Program Files\cosids\DATA\TMP\00510984.rtf.html
S 0012860
1
2
3
36. Secure fuel pipe (2) to support frame (1) • Secure 2x clip
S 0012919
1 2
37. Secure harness (1) for mass air flow meter to support frame (2) • Secure clip (3)
Page 17 of 20510984Exhaust Gas Recirculation Valve, Replace
02/01/2014file://C:\Program Files\cosids\DATA\TMP\00510984.rtf.html
S 0012861
1
2
3
38. Secure harness for charge pressure sensor to support frame (1) • Secure clip (3)
39. Secure charge pressure sensor and base adapter (2) to support frame • Push on
S 0012916
1 2
3
40. Install air cleaner assembly to support frame • Push on 4x locating peg (1)
Page 18 of 20510984Exhaust Gas Recirculation Valve, Replace
02/01/2014file://C:\Program Files\cosids\DATA\TMP\00510984.rtf.html
S 0012753
11
41. Install air intake duct (1) to air cleaner assembly (2) and front panel • Secure 2x clip
S 0012752
1
2
42. Connect harness connector (3) to mass air flow meter
43. Connect hose (2) to mass air flow meter (1) • Secure clip
Page 19 of 20510984Exhaust Gas Recirculation Valve, Replace
02/01/2014file://C:\Program Files\cosids\DATA\TMP\00510984.rtf.html
S 0012749
1
2
3
44. Connect hose (1) to oil filler on air cleaner assembly • Secure clip (2)
S 0012751
1 2
45. Connect battery negative lead
46. Program all volatile memories
47. Programming with Tech 2 is required after replacing the exhaust gas recirculation valve
Page 20 of 20510984Exhaust Gas Recirculation Valve, Replace
02/01/2014file://C:\Program Files\cosids\DATA\TMP\00510984.rtf.html