EGR end cap assembly – 2.

0 TDCI
(09.2011-09.2015), 2.0 TDCI motor (DW10C) 140 HP and 164 HP

Required tools:
- hex keys
- torx keys (so called star keys)
- socket wrenches
- screwdriver

1. Remove the motor’s plastic cover

2. The EGR is located under the intake manifold. It is necessary to disassemble several elements to gain access
to it. The operation is not complicated, it will take approx. 30-45 minutes (assembly + disassembly).

The EGR, or rather the outlet leading further to the collector is hidden here

3. Detach the oil inlet from the grip. It is fastened with a snap fit.
4. Detach the four marked plugs. Remember that the ignition must be turned off.

5. Detach the two grips – you can use a screwdriver.

Marked grips after detachment

6. Unscrew the marked bolts. Notice that they are not tightened in using force. Do not use force to tighten
them during later assembly.

7. For safety, detach the collector sensor, the bolt of which was unscrewed a minute ago. It is as easy as
removing it. You can clean it as well – do it carefully.

Sensor detachment
8. Loosen the band on the intake pipe of the intercooler. It is fastened to the pipe, so do not try to detach it,
just loosen it. Then, move the pipe downwards (firmly push it downwards until it is ejected).

Marked bolt on the band of the intercooler pipe.

9. Grab and pull the damper to eject it entirely. It will provide access to the EGR valve’s pipe.

Pull these two openings

10. Detach the grip with the plug from the black casing – the next step is to unscrew it.

Detached plug with the grip (this is easier than detach the grip from the plug)

11. Unscrew the black plastic element. It is mounted using three bolts. Due to hindered access, it is necessary to
use socket wrenches with extensions. The use of wrenches with extensions will prevent any problems. The
left top bolt is visible, while the other bolt is located slightly lower. It is placed rather deeply, but access to it
is relatively good. The third bolt is located on the right side and it easy to see it. The access to it is easy.
It is necessary to remove this element to gain access to the EGR pipe.

Unscrewed element with marked bolt sockets

 First bolt – easily visible

Second bolt – located slightly deeper – it can be reached by hand

 Third bolt on the right side

12. The EGR is accessible now. First, it is necessary to loosen the bolt at the collector.

Bolt to be unscrewed – Torx – here it is slightly unscrewed to make it easily visible

 Unscrewing the aforementioned bolt

13. Loosen the two bolts on the pipe protruding from the EGR valve. Place the end cap there and tighten it.

Loosen both bolts

 Insert the end cap here

14. Now reassemble the entire unit using the above instructions in the reverse order and enjoy your blanking
EGR valve.