Contents: Removal ⇩ Installation ⇩
Before disconnecting the battery, carefully read the "Disconnecting the Battery" section and follow all instructions therein.
GENERAL INFORMATION, Precautions when working with electrical equipment.
Removal
1. Disconnect the ground cable from the battery.
2. Remove the fan drive viscous coupling.
COOLING SYSTEM: Td6, REPAIR WORK, Viscous fan clutch.
3. Prepare a suitable container to drain some of the coolant.
4. Loosen the clamp and disconnect the coolant hose from the EGR cooler.
CAUTION: Close open ends of pipes immediately after disconnection with plugs to prevent foreign particles from entering the system.
5. Loosen the clamp and disconnect the hose from the EGR thermostatic valve.
6. Loosen the screw and remove the clamp securing the exhaust gas supply line to the EGR valve.
7. Loosen the screws and remove the clamps securing the exhaust pipes to the EGR cooler.
8. Remove the 3 Allen screws securing the EGR cooler and remove the cooler.
9. Remove the clamp securing the exhaust pipe to the cooler and remove the pipe.
NOTE: If disassembly was performed only to provide access to other system components, no further disassembly operations should be performed.
10. Remove the 2 EGR thermostatic valve mounting bolts and remove the valve. Remove and discard the old thermostatic valve O-ring.
Installation
1. Clean the mating surfaces of the thermostatic valve.
2. Install the new thermostatic valve O-ring.
3. Install the EGR thermostatic valve in place and tighten the mounting bolts to a torque of 10 N·m.
4. Clean the mating surfaces of the EGR cooler.
5. Install the EGR cooler in place, tighten the Allen screws, but do not tighten them.
6. Clean the mating surfaces of the exhaust gas supply line to the cooler.
7. Connect the exhaust pipes to the cooler, install the mounting clamps and tighten the screws.
8. Tighten the cooler mounting Allen screws to 25 Nm.
9. Connect the coolant hose to the EGR thermostatic valve fitting and secure with a clamp.
10. Connect the coolant hose to the EGR cooler fitting and secure with a clamp.
11. Install the fan viscous coupling.
COOLING SYSTEM: Td6, REPAIR WORK, Viscous fan clutch.
12. Connect the ground cable of the battery.
13. Add coolant to the cooling system.
COOLING SYSTEM: Td6, ADJUSTMENTS AND MAINTENANCE, Draining the coolant, flushing the system and filling.
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