Install, remove exhaust gas recirculation

AR14.20-D-1050SG

Install, remove exhaust gas recirculation

4.8.15

Engine

642.896/898/993 in model 906

Modification notes

26.9.14

Work procedure adapted to modified repair method.

1

Exhaust gas recirculation

6

Ventilation box

11

Oil filling line (transmission 722)

2

Vacuum line

7

Expansion reservoir

B60

Exhaust back pressure sensor

3

Aneroid capsule

8

Electrical connection

B60/4

Exhaust back pressure sensor

4

Electrical connection

9

Coolant hose

Y27/11

Exhaust gas recirculation positioner

5

Coolant hose

10

Front exhaust gas recirculation pipe

Y27/17

Exhaust gas recirculation positioner

1

Exhaust gas recirculation

16

Screw/bolts

24

Drain hose (for code KL5 (Fuel filter with water separator))

4

Electrical connection

17

Bracket

25

Seal

5

Coolant hose

18

Screw/bolt

B19/15

Exhaust gas recirculation cooler temperature sensor

11

Oil filling line (transmission 722)

19

Screw/bolt

B19/21

Exhaust gas recirculation cooler temperature sensor

12

Pressure lines

20

Electrical connection

B60

Exhaust back pressure sensor

13

Bracket

21

Bracket

B60/4

Exhaust back pressure sensor

14

Screw/bolts

22

Oil dipstick guide tube

B90/1

Exhaust gas recirculation cooler end position measurement sensor (engine 642.993)

15

Rear exhaust gas recirculation pipe

23

Drain pipe (for code KL5 (Fuel filter with water separator))

 Danger !

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 Danger !

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 

Remove/install

1

Disconnect battery ground line

AR54.10-D-0003SD

2

Drain off coolant

AR20.00-D-1140SD

3

Remove expansion reservoir (7)

AR20.30-D-4950SD

4

Lift/jack up vehicle

AR00.60-D-1000H

5

Remove rear exhaust gas recirculation pipe (15) at the EGR (1)

ENGINE 642.896/898 in MODEL 906

AR14.20-D-1060SD

ENGINE 642.993 in MODEL 906

AR14.20-D-1060S

6

Lower vehicle

7

Disconnect electrical connection (8) at exhaust gas recirculation positioner (Y27/11 or Y27/17)

8

Disconnect electrical connection at exhaust gas recirculation cooler temperature sensor (B19/15 or B1921)

9

Expose electrical line for exhaust gas recirculation cooler temperature sensor (B19/15 or B19/21)

10

Detach coolant hoses (5, 9) on EGR (1)

 Collect the escaping coolant in a suitable container.

 Installation: Check clamps for damage.

11

Remove screw/bolts from front exhaust gas recirculation pipe (10) to exhaust gas recirculation valve

AR14.20-D-1060SG

12

Detach drain hose (24) at drain pipe (23)

Engine 642.896/898/993 in model 906
with code KL5 (Fuel filter with water separator)

13

Detach vacuum line (2) at the aneroid capsule (3)

14

Disconnect electrical connection (4) from exhaust back pressure sensor (B60 or B60/4)

15

Remove oil dipstick guide tube (22) on bracket (21) and press to the side

16

Disconnect electrical connection (20) at exhaust gas recirculation cooler end position detection sensor (B90/1)

Engine 642.993 in model 906

17

Remove oil filler line (11) bracket (13) and the EGR (1) and push to side

Engine 642.896/898/993 in model 906 with transmission 722

18

Unfasten clamp of the pressure lines (12) from bracket (13)

Engine 642.896/898 in model 906

19

Remove bracket (13) at the EGR (1)

20

Remove screws/bolts (14) from EGR (1)

 Bolt, exhaust gas recirculation bypass flap to bracket

*BA14.20-N-1023-01H

 Set of flexible head wrenches

*001589810900

21

Remove screw/bolts (16) at bracket (17) and the EGR (1)

 Bolt, exhaust gas recirculation valve housing to bracket

*BA14.20-N-1022-01H

 Set of flexible head wrenches

*001589810900

22

Remove screw/bolt (19)

 The screw/bolt (19) cannot be pulled out.

 Bolt, exhaust gas recirculation valve housing to bracket

*BA14.20-N-1022-01H

23

Remove screw/bolt (18) and remove EGR (1) upwards

 Installation: Before placing the EGR (1), insert the screw/bolt (19) into the bores on the flange of the EGR (1).

 Bolt, exhaust gas recirculation valve housing to bracket

*BA14.20-N-1022-01H

 Set of flexible head wrenches

*001589810900



Clean

24

Clean sealing surfaces on the EGR (1)

25

Install in the reverse order

 Danger !

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

26

Carry out an engine test run and check in the area of the EGR (1) for leaktightness

 Exhaust gas recirculation

Number

Designation

Engine 642.8 in model 906

Engine 642.993 in model 906

BA14.20-N-1022-01H

Bolt, exhaust gas recirculation valve housing to bracket

M8x20

Nm

28

28

M8x80

Nm

20

20

 Exhaust gas recirculation

Number

Designation

Engine 642.8 in model 906

Engine 642.993 in model 906

BA14.20-N-1023-01H

Bolt, exhaust gas recirculation bypass flap to bracket

Nm

20

20