Removal/installation procedure
Attention! It is necessary to make sure that all components have cooled down. Then carry out the work.
1. Disconnect the negative battery cable.
2. Remove the decorative cover. See Section 1B, "Engine Mechanical System - 2.0 Diesel".
3. Remove the air intake hoses and ducts. See Section 1B, "Engine Mechanical System - 2.0 Diesel".
4. Drain the engine coolant. See Section 1D1, "Engine Cooling - 2.0 Diesel".
5. Remove the battery and shelf. See Section 1E1, Engine Electrical - 2.0 Diesel.
6. Remove the ECM. See "ECU Controller" in this section.
7. Remove the decorative cover bracket. See "Vacuum pump" in this section.
8. Remove the engine wiring harness bracket. See "Vacuum pump" in this section.
9. Remove the EGR cooler outlet pipe.
10. Disconnect the hose from the expansion tank to the water pipe.
11. Disconnect the hose from the heater to the water pipe.
12. Remove the water pipe mounting bolt from the front of the engine cylinder block.
13. Remove the EGR valve.
14. Remove the water pipe mounting bolts from the rear and side parts of the engine cylinder block.
15. Lower the water tube.
16. Remove the EGR cooler.
17. Remove the EGR cooler inlet pipe from the exhaust manifold.
Installation procedure
1. Install the EGR cooler inlet pipe to the exhaust manifold.
2. Install the EGR cooler with the engine wiring harness bracket.
Tighten
Tighten the EGR cooler inlet pipe retaining nuts to 33 Nm (24.3 ft·lbs).
Tighten the EGR cooler mounting bolt to 20 Nm (14.8 ft·lbs).
3. Install the EGR valve.
4. Screw the water pipe mounting bolt into the engine cylinder block.
Tighten
Tighten the exhaust gas recirculation valve mounting nuts (to the exhaust gas recirculation cooler) up to 20 Nm (14.8 ft·lbs).
Tighten the EGR valve mounting bolts (to the exhaust gas recirculation intake manifold) up to 20 Nm (14.8 ft·lbs).
Tighten the water pipe mounting bolt (M6) to 9 Nm (79.7 lbs.in).
Tighten the water pipe mounting bolt (M8) to 20 Nm (14.8 lbs.in).
5. Install the EGR cooler outlet pipe.
6. Screw the water pipe mounting bolt into the front part of the engine cylinder block.
Tighten
Tighten the EGR cooler outlet pipe mounting bolts and nuts to 20 Nm (14.8 ft·lbs).
Tighten the water pipe mounting bolt (M8) to 20 Nm (14.8 lbs.in).
[The original article can be found on the resource «ChevyMan.ru»]