Remove/install low-pressure exhaust gas recirculation cooler

AR14.20-P-7681MFF

Remove/install low-pressure exhaust gas recirculation cooler

29.11.2019

Engine

654 in model 118, 177, 247

Modification notes

29.11.2019

Document completely revised.

1

Low pressure exhaust gas recirculation cooler

8

Bolts

2

Bracket

9

Bolts

3

Coolant hose

10

Clip

4

Screw

11

Screw

5

Screw

12

Screw

6

Exhaust gas recirculation line

13

Screw

7

Exhaust gas recirculation line

14

Bolts

 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

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-Z-0001-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A



Remove

1

Drain off coolant.

AR20.00-P-1142MFF

2

Remove glow output stage together with the heat shield and place to one side with connected lines.

AR15.20-P-4500MFF

3

Remove low-pressure exhaust gas recirculation valve.

AR14.20-P-7683MFF

4

Remove screws (14).

5

Remove screws (9).

6

Remove screws (8).

7

Remove exhaust gas recirculation line (6).

8

Remove seals from the exhaust gas recirculation line (6).

9

Seal openings in the exhaust gas recirculation line (6), in the exhaust manifold, and in the high-pressure exhaust gas recirculation valve with stop plugs and protective covers.

 Set of plugs

*199589009800

 Set of protective caps

*001589029100

10

Remove screw (4) and turn bracket.

11

Open clamp (10) and remove coolant hose (3) from the low-pressure exhaust gas recirculation cooler (1).

 Hose clamp pliers

*454589003700

12

Seal coolant hose (3) with protective cover.

 Set of protective caps

*001589009100

13

Remove screw (5).

14

Remove screws (12).

15

Remove screw (13).

16

Remove screw (11) and remove bracket (2).

17

Remove low-pressure exhaust gas recirculation cooler (1).

18

Remove O-ring from the coolant feed.

 Assembly tool

*000589936300

19

Remove seal from the exhaust gas recirculation line (7).

20

Seal openings in the low-pressure exhaust gas recirculation cooler (1) and in the opening of the exhaust gas recirculation line (7) with stop plugs and protective covers.

 Set of protective caps

*001589009100

 Set of plugs

*199589009800



Install

21

Remove stop plug and protective covers from the openings in the low-pressure exhaust gas recirculation cooler (1) and exhaust gas recirculation line (7).

 Set of protective caps

*001589009100

 Set of plugs

*199589009800

22

Attach seal to the exhaust gas recirculation line (7).

 Replace seal.

23

Attach O-ring to the coolant feed.

 Replace O-ring.

 Assembly tool

*000589936300

24

Install low-pressure exhaust gas recirculation cooler (1).

25

Position bracket for screw (4) on the coolant feed.

 Replace screw (4).

 Holder, water supply for low-pressure exhaust gas recirculation cooler to coolant line

*BA14.20-P-1023-01Q

26

Install bracket (2) and screw in screw (11).

 Replace bolt (11).

 Screw, bracket for low-pressure exhaust gas recirculation cooler to cylinder head cover/low-pressure exhaust gas recirculation cooler/lifting lug

*BA14.20-P-1015-01Q

27

Remove stop plug and protective covers from the openings of the exhaust gas recirculation line (6) in the exhaust manifold and in the high-pressure exhaust gas recirculation valve.

 Set of plugs

*199589009800

 Set of protective caps

*001589029100

28

Screw in screws of the low-pressure exhaust gas recirculation cooler (1).

AR14.20-P-0001-02MFF

 Replace all screws/bolts with new ones.

 Bolt, low pressure exhaust gas recirculation cooler to chain case cover/bracket

*BA14.20-P-1014-01Q

 Screw, bracket for low-pressure exhaust gas recirculation cooler to cylinder head cover/low-pressure exhaust gas recirculation cooler/lifting lug

*BA14.20-P-1015-01Q

 Bolt, high pressure exhaust gas recirculation line to exhaust manifold

*BA14.20-P-1021-01Q

 Holder, water supply for low-pressure exhaust gas recirculation cooler to coolant line

*BA14.20-P-1023-01Q

 Bolt, high pressure EGR line to high pressure exhaust gas recirculation valve

*BA14.20-P-1025-01Q

 Bolt, high pressure exhaust gas recirculation line to intermediate holder

*BA14.20-P-1026-01Q

29

Screw in screws (12).

 Screws (12).

 Bolt, low pressure EGR line to low pressure exhaust gas recirculation cooler

*BA14.20-P-1008-01Q

30

Remove protective cover from coolant hose (3).

 Set of protective caps

*001589009100

31

Attach coolant hose (3) to the low-pressure exhaust gas recirculation cooler (1).

 Hose clamp pliers

*454589003700

32

Install low-pressure exhaust gas recirculation valve.

AR14.20-P-7683MFF

33

Attach glow output stage together with the heat shield.

AR15.20-P-4500MFF

 Only install upper engine cover after the leak test.

34

Fill in coolant.

AR20.00-P-1142MFF



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

AS00.00-Z-0005-01A

35

Perform engine test run and check engine for proper operation and leak tightness.

36

Install upper engine cover.

AR01.10-P-2405MFF

 Exhaust gas recirculation

Number

Designation

Engine 654

BA14.20-P-1008-01Q

Bolt, low pressure EGR line to low pressure exhaust gas recirculation cooler

Stage 1

Nm

8

Stage 2

°

90

 Exhaust gas recirculation

Number

Designation

Engine 654

BA14.20-P-1014-01Q

Bolt, low pressure exhaust gas recirculation cooler to chain case cover/bracket

Stage 1

Nm

8

Stage 2

°

30

 Exhaust gas recirculation

Number

Designation

Engine 654

BA14.20-P-1015-01Q

Screw, bracket for low-pressure exhaust gas recirculation cooler to cylinder head cover/low-pressure exhaust gas recirculation cooler/lifting lug

Stage 1

Nm

8

Stage 2

°

30

 Exhaust gas recirculation

Number

Designation

Engine 654

BA14.20-P-1021-01Q

Bolt, high pressure exhaust gas recirculation line to exhaust manifold

Stage 1

Nm

12

Stage 2

°

90

 Exhaust gas recirculation

Number

Designation

Engine 654

BA14.20-P-1023-01Q

Holder, water supply for low-pressure exhaust gas recirculation cooler to coolant line

Stage 1

Nm

8

Stage 2

°

30

 Exhaust gas recirculation

Number

Designation

Engine 654

BA14.20-P-1025-01Q

Bolt, high pressure EGR line to high pressure exhaust gas recirculation valve

Stage 1

Nm

10

Stage 2

°

60

 Exhaust gas recirculation

Number

Designation

Engine 654

BA14.20-P-1026-01Q

Bolt, high pressure exhaust gas recirculation line to intermediate holder

Stage 1

Nm

8

Stage 2

°

60