:  Aug 9, 2004



. Disconnect the battery ground cable.

. Remove the turbocharger.

. Drain the cooling system.

. Remove the battery tray.

. Remove the LH EGR valve outlet tube.

. Disconnect the coolant outlet hose from the LH EGR valve.
  Release the clip.




. Release the LH EGR valve inlet tube.
  Remove the two support bracket retaining bolts.
  Remove the support bracket.
  Remove and discard the retaining clip.




. Remove the LH EGR valve inlet tube.
  Remove the two retaining bolts.
  Remove and discard the gasket.




. Disconnect the LH EGR valve electrical connector.



. Disconnect the coolant inlet hose from the LH EGR valve.
  Release the clip.




. Remove the LH EGR valve.
  Remove the three retaining bolts.




. Remove the LH exhaust manifold heat shield.
  Remove the two retaining bolts.




. Remove the three exhaust cross-over pipe retaining nuts.



. Remove the LH exhaust manifold.
  Remove the six retaining nuts.




. Remove and discard the LH exhaust manifold gasket.
  Remove and discard the studs.




. Tighten the LH exhaust manifold retaining studs to 13 Nm (10 lb.ft).
  Install a new gasket.

. :
  Tighten the retaining nuts in the sequence shown.

Install the LH exhaust manifold.
  Tighten the nuts to 24 Nm (18 lb.ft).




. Install the three exhaust cross-over pipe retaining nuts.
  Tighten the nuts to 24 Nm (18 lb.ft).

. Install the LH exhaust manifold heat shield.
  Install the two retaining bolts and tighten to 10 Nm (7 lb.ft).

. Install the LH EGR valve.
  Install the three EGR valve retaining bolts, but do not fully tighten at this stage.

. :
  Do not fully close the retaining clip at this stage.

Install the LH EGR valve inlet tube.
  Install a new retaining clip.
  Install a new gasket.
  Loosely install the two EGR valve inlet tube retaining bolts.

. Fully close the retaining clip.

. Tighten the two EGR valve inlet tube retaining bolts to 10 Nm (7 lb.ft).

. Tighten the three EGR valve retaining bolts to 10 Nm (7 lb.ft).

. Install the support bracket.
  Tighten the two retaining bolts to 10 Nm (7 lb.ft).

. Connect the coolant inlet hose to the LH EGR valve.

. Connect the LH EGR valve electrical connector.

. Connect the coolant outlet hose to the LH EGR valve.

. Install the LH EGR valve outlet tube.

. Install the battery tray.

. Install the turbocharger.

. Connect the battery ground cable.

. Refill and bleed the cooling system.