EGR Cooler: Service and Repair

Bypass Flap with Exhaust Gas Recirculation Cooler

- Drain the cooling system. Refer to --> [ Cooling System, Draining and Filling ] [1][2][3]Cooling System, 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 - 1 - and move the coolant pipe - 2 - back.





- Remove the Exhaust Gas Recirculation (EGR) 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 pipes in the cylinder head area and remove their brackets.

- 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 hex bolt of the same size and strength category.

- Fill the cooling system. Refer to --> [ Cooling System, Draining and Filling ] [1][2][3]Cooling System, Draining and Filling.