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1 1 Page 1 of 20 Exhaust Gas Recirculation Valve, Replace J 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) 1 2 S Disconnect hose (2) from mass air flow meter (1) Release clip 4. Disconnect harness connector (3) from mass air flow meter 5. Remove air intake duct (1) from air cleaner assembly (2) and front panel Release 2x clip

2 1 1 Page 2 of Remove air cleaner assembly from support frame Pull off from 4x locating peg (1) 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)

3 Page 3 of Release fuel pipe (2) from support frame (1) Release 2x clip 10. Release harness (1) for mass air flow meter from support frame (2) Release clip (3)

4 1 Page 4 of 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)

5 3 Page 5 of 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 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)

6 Page 6 of Remove O ring from duct assembly 17. Remove radiator grille from vehicle Remove 5x bolt (1) Release from 10x retaining clip

7 Page 7 of Remove intercooler from upper front panel Remove 2x bolt (1) Release 2x locating pin of intercooler from 2x rubber guide Pull upwards

8 Page 8 of Remove dipstick with guide tube assembly from engine Remove bolt (1) Remove O ring Install new blanking plug

9 Page 9 of Remove throttle valve assembly from engine Disconnect harness connector Release fuel pipe from clip Remove 6x bolt Remove gasket Release 2x clip 21. Remove exhaust gas recirculation (EGR) pipe from cooler and control valve Remove 4x bolt, 2x gasket

10 1 4 Page 10 of 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 Install 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

11 1 4 Page 11 of Install EGR pipe to cooler and control valve Clean mating surfaces Install 2x new gasket Install 4x bolt 25 Nm 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

12 Page 12 of Install dipstick with guide tube assembly to engine Remove blanking plug Install new O ring Install bolt (1) 10 Nm 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

13 Page 13 of Install radiator grille to vehicle Secure to 10x retaining clip Install 5x bolt (1) 4 Nm

14 Page 14 of 20 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

15 Page 15 of Install intercooler outlet pipe to engine compartment Secure 3x clip Connect harness connector

16 3 Page 16 of 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)

17 1 Page 17 of Secure fuel pipe (2) to support frame (1) Secure 2x clip 37. Secure harness (1) for mass air flow meter to support frame (2) Secure clip (3)

18 Page 18 of 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 40. Install air cleaner assembly to support frame Push on 4x locating peg (1)

19 1 1 Page 19 of Install air intake duct (1) to air cleaner assembly (2) and front panel Secure 2x clip 42. Connect harness connector (3) to mass air flow meter 43. Connect hose (2) to mass air flow meter (1) Secure clip

20 1 Page 20 of Connect hose (1) to oil filler on air cleaner assembly Secure clip (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

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