High Pressure Exhaust Gas RECIRCULATION Cooler (G1947549): Removal

WARNING: This page is about a different variant/trim than selected.

CAUTION: Before disconnecting any components, make sure the area is clean and free from foreign material. When disconnected all openings must be sealed.

NOTE:

This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
This procedure contains illustrations showing certain components removed to provide extra clarity.

Raise and support the vehicle on a suitable 2 post lift.
Refer to: LIFTING
Disconnect the startup battery ground cable.
Refer to: STARTUP BATTERY DISCONNECT AND CONNECT
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Remove the engine cover.
Drain the coolant system.
Refer to: COOLING SYSTEM DRAINING AND VACUUM FILLING
Remove the coolant expansion tank.
Refer to: COOLANT EXPANSION TANK
Always follow the Diesel fuel system health and safety precautions, when carrying out any repairs to the fuel system.
Refer to: DIESEL FUEL SYSTEM HEALTH AND SAFETY PRECAUTIONS
CAUTION: Be prepared to collect escaping fuel.

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Disconnect the 3 fuel pipes.
CAUTION: Be prepared to collect escaping coolant.

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Disconnect the high pressure Exhaust Gas Recirculation (EGR) cooler outlet coolant hose.
CAUTION: Be prepared to collect escaping coolant.

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Disconnect the high pressure EGR cooler inlet coolant hose.
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Disconnect the 3 electrical connectors for the high pressure EGR cooler.
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Disconnect the EGR pressure monitoring system and reposition away from the high pressure EGR cooler assembly.
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Disconnect the oil gauge bracket assembly.
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Disconnect the high pressure EGR cooler pipe from the high pressure EGR valve assembly.
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Release the high pressure EGR cooler clamp.
CAUTION: Discard the gasket.

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Remove the high pressure EGR cooler assembly and discard the gasket.
NOTE: Do not disassemble further if the component is removed for access only.

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Remove the temperature sensor from the high pressure EGR cooler assembly.