Exhaust Gas Recirculation Valve, Replace J982500ww2.justanswer.co.uk/uploads/MA/markthebooler/2014-01-02... · 2014-01-02 · Exhaust Gas Recirculation Valve, Replace J982500 Remove

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)

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3. Disconnect hose (2) from mass air flow meter (1) • Release clip

4. Disconnect harness connector (3) from mass air flow meter

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5. Remove air intake duct (1) from air cleaner assembly (2) and front panel • Release 2x clip

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6. Remove air cleaner assembly from support frame • Pull off from 4x locating peg (1)

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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)



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9. Release fuel pipe (2) from support frame (1) • Release 2x clip

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10. Release harness (1) for mass air flow meter from support frame (2) • Release clip (3)



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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)

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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

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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)



16. Remove O ring from duct assembly

17. Remove radiator grille from vehicle • Remove 5x bolt (1)

• Release from 10x retaining clip



18. Remove intercooler from upper front panel • Remove 2x bolt (1)

• Release 2x locating pin of intercooler from 2x rubber guide – Pull upwards



19. Remove dipstick with guide tube assembly from engine • Remove bolt (1)

• Remove O ring

• Install new blanking plug



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20. Remove throttle valve assembly from engine • Disconnect harness connector

• Release fuel pipe from clip

• Remove 6x bolt

• Remove gasket – Release 2x clip

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21. Remove exhaust gas recirculation (EGR) pipe from cooler and control valve • Remove 4x bolt, 2x gasket



Install

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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

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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



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26. Install EGR pipe to cooler and control valve • Clean mating surfaces

• Install 2x new gasket

• Install 4x bolt 25 Nm

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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



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28. Install dipstick with guide tube assembly to engine • Remove blanking plug

• Install new O ring

• Install bolt (1) 10 Nm

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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



30. Install radiator grille to vehicle • Secure to 10x retaining clip

• Install 5x bolt (1) 4 Nm



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



32. Install intercooler outlet pipe to engine compartment • Secure 3x clip

• Connect harness connector



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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)



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36. Secure fuel pipe (2) to support frame (1) • Secure 2x clip

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37. Secure harness (1) for mass air flow meter to support frame (2) • Secure clip (3)



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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

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



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41. Install air intake duct (1) to air cleaner assembly (2) and front panel • Secure 2x clip

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42. Connect harness connector (3) to mass air flow meter

43. Connect hose (2) to mass air flow meter (1) • Secure clip



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44. Connect hose (1) to oil filler on air cleaner assembly • Secure clip (2)

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45. Connect battery negative lead

46. Program all volatile memories

47. Programming with Tech 2 is required after replacing the exhaust gas recirculation valve



Documents

Exhaust Gas Recirculation Valve, Replace J982500ww2.justanswer.co.uk/uploads/MA/markthebooler/2014-01-02... · 2014-01-02 · Exhaust Gas Recirculation Valve, Replace J982500 Remove