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Exhaust Gas Recirculation Valve Cooler Replacement

1. Remove the engine sight shield. Refer to Engine Sight Shield Replacement .
2. Remove the dash upper extension panel opening cover. Refer to Dash Upper Extension Panel Opening Cover Replacement .
3. Remove the battery tray. Refer to Battery Tray Replacement .
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
5. Drain the cooling system. Refer to Cooling System Draining and Filling .
6. Remove the exhaust gas recirculation pipe. Refer to Exhaust Gas Recirculation Pipe Replacement .
7. Lower the vehicle.
8. For vehicles with MT: Disconnect the transmission gear lever and selector cable from the transmission. Refer to Manual Gearbox Gear Lever and Selector Lever Cable Replacement .

For vehicles with AT: Disconnect the range selector lever cable from the automatic transmission. Refer to Range Selector Lever Cable Replacement .




9. Disconnect the vacuum solenoid valve wiring harness plug (8).
10. Disconnect the exhaust gas recirculation valve wiring harness plug (9).
11. Disconnect the inlet actuator valve wiring harness plug (7).
12. Disconnect the fuel injection rail pressure sensor wiring harness plug (3).
13. Disconnect the 4 glow plug wiring harness plugs (5).
14. Disconnect the 4 fuel injector wiring harness plugs (1).
15. Unclip the 4 engine wiring harness clips (2, 4) from the camshaft cover.
16. Unclip the engine wiring harness conduit (6) in top direction from the 3 exhaust gas recirculation cooler brackets. Hang the engine wiring harness aside.
17. Remove the engine coolant air bleed hose. Refer to Engine Coolant Air Bleed Hose Replacement : 2.0L Diesel LNP .
18. Remove the vacuum pump hose. Refer to Vacuum Pump Hose Replacement .
19. Remove the inlet manifold tuning valve vacuum control solenoid valve hose. Refer to Inlet Manifold Tuning Valve Vacuum Control Solenoid Valve Hose Replacement .
20. Unclip the engine wiring harness retaining clip from the charge air cooler outlet front hose.
21. Unclip the transmission vent hose from the charge air cooler outlet front hose.



22. Remove the charge air cooler outlet front hose bracket bolt (2).
23. Loosen the charge air cooler outlet front hose to rear hose clip (4).
24. Detach the charge air cooler outlet front hose (1) along with the clamp (4) from the charge air cooler outlet rear hose (3).



25. Unclip the 2 wiring harness retaining clips from the charge air cooler outlet rear hose (2).
26. Place a suitable tool at the marked position (arrow) and rotate the lock ring (1) anti-clockwise.
27. Detach the charge air cooler outlet rear hose (2) from the throttle body (3).
28. Remove the charge air cooler outlet rear hose (2).
29. Remove the exhaust gas recirculation manifold cooling return hose. Refer to Exhaust Gas Recirculation Manifold Cooling Return Hose Replacement : 2.0L Diesel LNP .
30. Remove the exhaust gas recirculation cooling feed hose. Refer to Exhaust Gas Recirculation Valve Cooling Feed Hose Replacement .
31. Remove the turbocharger coolant return pipe from the exhaust gas recirculation cooler. Refer to Turbocharger Coolant Return Pipe Removal .



32. Remove the exhaust gas recirculation cooler nut (5) and the 5 exhaust gas recirculation cooler bolts (3, 4 and 6).
33. Remove the exhaust gas recirculation cooler (2) and the gasket (1).

1. Install the exhaust gas recirculation cooler (2) and a NEW gasket (1).

Caution: Refer to Fastener Caution in the Preface section.

2. Install the 5 exhaust gas recirculation cooler bolts (3, 4 and 6) and the exhaust gas recirculation cooler nut (5) and tighten to 25 N·m (18 lb ft).
3. Install the turbocharger coolant return pipe to the exhaust gas recirculation cooler. Refer to Turbocharger Coolant Return Pipe Removal .
4. Install the exhaust gas recirculation cooling feed hose. Refer to Exhaust Gas Recirculation Valve Cooling Feed Hose Replacement .
5. Install the exhaust gas recirculation manifold cooling return hose. Refer to Exhaust Gas Recirculation Manifold Cooling Return Hose Replacement : 2.0L Diesel LNP .




Note: Note: Ensure that the retaining ring (1) is locked.

6. Install the charge air cooler outlet rear hose (2) to the throttle body (3).
7. Clip in the 2 wiring harness retaining clips to the charge air cooler outlet rear hose (2).



8. Install the charge air cooler outlet front hose (1) along with the clamp (4) to the charge air cooler outlet rear hose (3).
9. Install the charge air cooler outlet front hose bracket bolt (2) and tighten to 9 N·m (80 lb in).
10. Tighten the charge air cooler outlet front hose to rear hose clip (4) to 4 N·m (35 lb in).
11. Clip in the transmission vent hose to the charge air cooler outlet front hose.
12. Clip in the engine wiring harness retaining clip to the charge air cooler outlet front hose.
13. Install the inlet manifold tuning valve vacuum control solenoid valve hose. Refer to Inlet Manifold Tuning Valve Vacuum Control Solenoid Valve Hose Replacement .
14. Install the vacuum pump hose. Refer to Vacuum Pump Hose Replacement .
15. Install the engine coolant air bleed hose. Refer to Engine Coolant Air Bleed Hose Replacement : 2.0L Diesel LNP .



16. Position the engine wiring harness on the vehicle.
17. Clip the engine wiring harness conduit (6) to the 3 exhaust gas recirculation cooler brackets.
18. Clip the 4 engine wiring harness clips (2, 4) to the camshaft cover.
19. Connect the 4 fuel injector wiring harness plugs (1).
20. Connect the fuel injection rail pressure sensor wiring harness plug (3).
21. Connect the 4 glow plug wiring harness plugs (5).
22. Connect the inlet actuator valve wiring harness plug (7).
23. Connect the exhaust gas recirculation valve wiring harness plug (9).
24. Connect the vacuum solenoid valve wiring harness plug (8).
25. For vehicles with MT: Connect the transmission gear lever and selector cable from the transmission. Refer to Manual Gearbox Gear Lever and Selector Lever Cable Replacement .

For vehicles with AT: Connect the range selector lever cable from the automatic transmission. Refer to Range Selector Lever Cable Replacement .

26. Raise the vehicle.
27. Install the exhaust gas recirculation pipe. Refer to Exhaust Gas Recirculation Pipe Replacement .
28. Fill the engine cooling system. Refer to Cooling System Draining and Filling .
29. Lower the vehicle.
30. Install the battery tray. Refer to Battery Tray Replacement .
31. Install the dash upper extension panel opening cover. Refer to Dash Upper Extension Panel Opening Cover Replacement .
32. Install the engine sight shield. Refer to Engine Sight Shield Replacement .