Remove/install exhaust gas recirculation valve

AR14.20-D-7662WE

Remove/install exhaust gas recirculation valve

14.02.2017

Engine

651 in model 900

Engine

651.955/956/957 in model 906

Modification notes

09.02.2017

Work procedure revised

Operation steps 6 to 28

Shown on engine 651.955

1

Electrical connection

6

Screw/bolts

11

Screw/bolts

2

Fuel hose

7

Screw/bolt

12

Retaining clamp

3

Fuel line

8

Bypass flap aneroid capsule

13

Electrical line

4

Bracket

9

Vacuum hose

Y27/15

Exhaust gas recirculation positioner

5

Screw/bolts

10

Bypass flap

Y93/1

Boost pressure control flap pressure transducer

Shown with code ZU8 (National version USA)

3

Fuel line

7

Screw/bolt

14

Shield

15

Screw/bolts

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 Warning

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

1

Drain off coolant

AR20.00-D-1140SD

2

Remove engine cover

AR01.10-D-2405WE

3

Remove vacuum reservoir

Engine 651 in model 900
Engine 651.955/957 in model 906

AR07.09-D-0001WE

4

Remove exhaust gas recirculation cooler

AR14.20-D-7665WE

5

Remove charge air distributor

AR09.41-D-8681WE

6

Unscrew screw/bolt (7)

7

Remove shield (14)

Engine 651.955/956/957 in model 906
with code ZU7 (National version for Canada)
Engine 651.955/956/957 in model 906
with code ZU8 (National version for USA)

 To do this, remove the screw/bolts (15).

8

Loosen and remove fuel hose (2) on high-pressure pump

 Seal connections.

 Pliers for click clamps

*171589003700

 Record plug

*129589009100

9

Place fuel line (3) to one side

10

Remove screw/bolts (6)

 Set of flexible head wrenches

*001589810900

11

Remove boost pressure control flap pressure transducer (Y93/1) with attached lines from bracket (4) and place to one side

12

Remove retaining clamp (12) with electrical line (13) from bracket (4)

13

Remove bracket (4)

 To do this, remove the screw/bolts (5).

14

Disconnect electrical connection (1) at exhaust gas recirculation positioner (Y27/15)

15

Remove exhaust gas recirculation positioner (Y27/15) with bypass flap (10)

 To do this, remove screw/bolts (11).

16

Remove vacuum hose (9) from bypass flap aneroid capsule (8)



Check

17

Check vacuum hose (9)

For damage



Replace vacuum hose (9).



Install

18

Attach vacuum hose (9) to bypass flap aneroid capsule (8)

19

Install exhaust gas recirculation positioner (Y27/15) with bypass flap (10)

AR14.20-D-7662-01WE

 Screw in screw/bolts (11) to do this. Align exhaust gas recirculation positioner (Y27/15) with bypass flap (10) and exhaust gas recirculation cooler relative to brackets on exhaust gas recirculation cooler.

 Replace seals.

 Bolt, bypass flap with exhaust gas recirculation valve to exhaust gas recirculation line

*BA14.20-N-1031-01H

 Set of flexible head wrenches

*001589810900

20

Connect electrical connection (1) to exhaust gas recirculation positioner (Y27/15)

21

Install bracket (4)

 Screw in screw/bolts (5) to do this.

 Bolt, exhaust gas recirculation valve/bypass flap bracket to crankcase

*BA14.20-N-1030-01H

 Bolt, bracket to exhaust gas recirculation valve/bypass flap

*BA14.20-N-1029-01H

 Set of flexible head wrenches

*001589810900

22

Attach retaining clamp (12) with electrical line (13) to bracket (4)

23

Attach boost pressure control flap pressure transducer (Y93/1)

 Screw in screw/bolts (6) to do this.

 Set of flexible head wrenches

*001589810900

24

Position fuel line (3)



Check

25

Check clamp and fuel hose (2)

For damage



Replace clamp or fuel hose (2).

26

Mount fuel hose (2) on the high-pressure pump

 Pliers for click clamps

*171589003700

27

Install shield (14)

Engine 651.955/956/957 in model 906
with code ZU7 (National version for Canada)
Engine 651.955/956/957 in model 906
with code ZU8 (National version for USA)

 Screw in screw/bolts (15) to do this.

 M6

*BA00.10-N-1002-01A

28

Fasten fuel line (3)

 Screw in screw/bolt (7) to do this.

29

Install charge air distributor

AR09.41-D-8681WE

30

Install exhaust gas recirculation cooler

AR14.20-D-7665WE

31

Install vacuum reservoir

Engine 651 in model 900
Engine 651.955/957 in model 906

AR07.09-D-0001WE

32

Pour in coolant

AR20.00-D-1140SD



Check

 Warning

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 buttoned-up and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

33

Perform an engine test run and check exhaust gas recirculation system and fuel system for proper operation and leaktightness

 Visual inspection only.

34

Install engine cover

AR01.10-D-2405WE

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

8.8

10.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

9

13

Phosphated

Nm

9

12

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

12.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

16

Phosphated

Nm

14

 Exhaust gas recirculation

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA14.20-N-1029-01H

Bolt, bracket to exhaust gas recirculation valve/bypass flap

Nm

9

9

 Exhaust gas recirculation

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA14.20-N-1030-01H

Bolt, exhaust gas recirculation valve/bypass flap bracket to crankcase

Nm

9

9

 Exhaust gas recirculation

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA14.20-N-1031-01H

Bolt, bypass flap with exhaust gas recirculation valve to exhaust gas recirculation line

Nm

10

10