Captiva

Exhaust Gas Recirculation Valve Cooler Replacement - LNQ

Special Tools

BO 38185 Hose Clamp Pliers

For equivalent tools, refer toSpecial Tools .

1. Remove the fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement .



2. Remove the surge tank overflow hose. Refer to Radiator Surge Tank Overflow Hose Replacement
3. Disconnect the following:

•	EGR vacuum solenoid (1)

•	EGR valve (2)

•	Intake actuator assembly (3)

•	Engine harness conduit (4)




4. Remove the vacuum pump hose (1) and the manifold intake tuning valve hose (2).
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .



6. Remove the transmission mount bracket. Refer to Transmission Mount Bracket Replacement - Rear : FWD  → AWD .
7. Remove the EGR manifold cooling return hose (1) and the EGR valve cooling feed hose (2) , from the EGR cooler.



8. Remove the EGR pipe bolts (1), gasket (2) and seal (3).



9. Remove the EGR cooler support bracket bolt (1).




Note: The EGR cooler brace nut can be accessed from the side of the brace with a 1/4 inch extension and a swivel adapter.

10. Remove the EGR cooler brace nut (2).



11. Remove the EGR valve mounting bolts (1).



12. Remove the EGR valve and the EGR cooler (2) as one assembly.
13. Discard the EGR valve gasket (1).



14. Disconnect the EGR cooling feed hose (2).
15. Remove the EGR cooler bolts (1).
16. Separate the EGR cooler (5) from the EGR valve (4) and discard the gasket (3).

1. Install the EGR cooler (5), with a NEW gasket (3), to the EGR valve assembly (4).

Caution: Refer to Fastener Caution in the Preface section.

2. Tighten the EGR bolts (1) to 25 N·m (18 lb ft).



3. Position the EGR valve and cooler assembly (2) to the cylinder head with a NEW gasket (1).



4. Install the EGR valve assembly bolts (1) and tighten to 25 N·m (18 lb ft).



5. Install the EGR cooler brace nut (2) to the cylinder head and tighten to 25 N·m (18 lb ft).




Note: The EGR cooler support nut can be accessed from the side of the brace with a 1/4 inch extension and a swivel adapter.

6. Install the EGR cooler support nut (1) to the cylinder head and tighten to 25 N·m (18 lb ft).



7. Install the EGR manifold cooling return hose (1) and the EGR valve cooling feed hose (2).



8. Install the EGR pipe (4) to the intake manifold and EGR valve with a NEW gasket (2) and seal (3).
9. Tighten the bolts (1) to 25 N·m (18 lb ft).



10. Install the vacuum pump hose (1) and the manifold tuning valve hose (2).
11. Install the surge tank overflow hose. Refer to Radiator Surge Tank Overflow Hose Replacement .



12. Position the engine harness conduit (4) onto the EGR cooler tabs.
13. Connect the following:

•	EGR valve regulator solenoid (1)

•	EGR valve (2)

•	Intake actuator assembly (3)

14. Install the fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement .