Removing the exhaust gas recirculation (EGR) cooler assembly

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2006 Volvo S80, 2005 Volvo S80, 2004 Volvo S80, 2003 Volvo S80, and 2002 Volvo S80. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Exhaust Gas Recirculation Cooler Assembly

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

the hose to the intake manifold
the two coolant hoses
the connector for the radiator valve
the clamp for the flexible hose and exhaust manifold
the three screws retaining the cooler.

NOTE:

Keep the steel seal between the flexible hose and the exhaust manifold when the exhaust gas recirculation (EGR) cooler is removed.

Fig 2: Ground Lead, Coolant Hose, Charge Air Pipe And Clamps

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

the ground lead mounting on the sub-frame
the hose to the charge air pipe under the engine
the engine coolant hose from the pipe at the rear of the engine
the vacuum hose from the mountings and the clamp on the gearbox
the screw for the servo pipe clamp on the sub-frame.