Exhaust Gas Recirculation System Cooler (Freelander 2)

Removing

1. Raise and support the vehicle.

WARNING: Place secure stands under the vehicle.

2. Remove the center panel of the additional partition. Refer to Procedure: Additional Bulkhead Center Panel - 2.2L Duratorq - Td4 (501-02 Front body panels, Removal and installation).

3. Drain the coolant. Refer to Procedure: Drain/Fill Coolant and Bleed Cooling System (303-03B Engine Cooling - 2.2L Duratorq - Td4, General Procedures).

4. Remove the heated oxygen sensor (HO2S). Refer to Procedure: Heated Oxygen Sensor (HO2S) (303-14B Electronic controls - 2.2L Duratorq - Td4, Removal and installation).







8.

Plug all openings. Install new plugs. Reject the element.

11.

CAUTION: Discard items.

13.

NOTE: Do not proceed with further dismantling if the element is removed only for access. Discard the gasket.

Installation

1. Install the EGR valve. Tightening torque: 10 Nm

CAUTION: Clean the element of dirt, grease and foreign matter.

2. Install the EGR cooler.



3. Install nuts and bolt but do not fully tighten yet.

4. Tighten the nuts in the sequence shown. Tightening torque: 6 Nm

5. Tighten the bolts in the order shown in the figure. Tightening torque: 10 Nm

6. Install the EGR cooler to the exhaust manifold. Tightening torque: 10 Nm

Clean the element from dirt, grease and foreign particles. Make sure the new items are installed.

7. Connect the EGR valve electrical connector.

8. Install the exhaust manifold heat shield. Tightening torque: 10 Nm

9. Install the EGR pipe between the cooler intake manifold. Tightening torque: 10 Nm

Clean the element from dirt, grease and foreign particles. Make sure the new item is installed.

10. Connect coolant hoses and secure with clips.

11. Install the HO2S harness bracket. Tightening torque: 8 Nm

12. Install the HO2S. Refer to Procedure: Heated Oxygen Sensor (HO2S) (303-14B Electronic controls - 2.2L Duratorq - Td4, Removal and installation).

13. Fill the cooling system with coolant and remove air from the system. Refer to Procedure: Drain/Fill Coolant and Bleed Cooling System (303-03B Engine Cooling - 2.2L Duratorq - Td4, General Procedures).

14. Install the center panel of the additional partition. Refer to Procedure: Additional Bulkhead Center Panel - 2.2L Duratorq - Td4 (501-02 Front body panels, Removal and installation).