Removal procedure
Attention! Do not remove if exhaust manifold parts are hot.
1. Disconnect the negative battery cable.
2. Remove decorative cover. See «Decorative cover» in this section.
3. Remove the hoses and ducts of the charge air system. See «Air injection system» in this section.
4. Remove the crankcase breather valve (PCV) and adapter. See «Crankcase ventilation valve and adapter (PCV)» in this section.
5. Remove exhaust heat shield.
6. Remove pre-catalytic converter. See Section 1G1, Exhaust System - 2.0 Diesel.
7. Remove the turbocharger from the exhaust manifold. See Part 1F1, Engine Controls - 2.0 Diesel.
8. Remove the EGR cooler inlet pipe from the EGR valve, together with the gasket.
9. Remove the exhaust manifold with the EGR cooler inlet pipe.
10. Remove the EGR cooler intake pipe from the exhaust manifold.
Installation procedure
1. Install the EGR cooler intake pipe to the exhaust manifold.
2. Install the exhaust manifold to the cylinder head with a new gasket.
3. Install the EGR cooler inlet pipe to the EGR valve with a new gasket.
Tighten
Tighten the EGR cooler inlet pipe nuts (to exhaust manifold) up to 33 Nm (24.3 lb-ft).
Tighten exhaust manifold nuts to 33 Nm (24.3 lb-ft).
Tighten the EGR cooler inlet pipe bolts (to the EGR valve) up to 20 Nm (14.8 lb-ft).
4. Install the exhaust manifold heat shield.
Tighten
Tighten the exhaust manifold heat shield bolt and nuts to 20 Nm (14.8 lb-ft).