Remove/install exhaust gas recirculation line upstream of exhaust gas recirculation cooler

AR14.20-G-1061MG

Remove/install exhaust gas recirculation line upstream of exhaust gas recirculation cooler

03.04.2019

Engine

935.9 in model 800.011

1

Air intake pipe

2

Coolant lines

3

Bracket

4

Coolant pipe

5

Coolant pipe

6

Heat shield

7

Screws/bolts

8

Clamping bracket

9

Screws/bolts

10

Exhaust gas recirculation line

11

Exhaust manifold

12

Exhaust gas recirculation cooler

13

Seal

 Danger

Risk of explosion due to escaping combustible gas or overheating of gas cylinders.Risk of injury caused by burns to skin and eyes. Risk of frostbite to body parts caused by escaping gas and by touching components near the valves when emptying gas cylinders. Risk of poisoning or suffocation caused by inhaling gas.

Remove any sources of ignition.
Protective clothing, safety gloves and safety glasses must always be worn.
Ensure that the work area is adequately ventilated.
When working on vehicles at ambient temperatures over 60 °C, all gas cylinders must be removed.

AS00.00-Z-0018-01A

 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 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

 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

 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 self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

Notes on work safety regulations for vehicles with natural gas-powered engines

AH00.10-N-1000-04A

 

Remove/install

1

Remove air intake pipe (1).

 See information from body manufacturer.

2

Remove coolant lines (2) from bracket (3).

3

Remove coolant pipes (4, 5) from bracket (3).

4

Remove the bracket (3).

5

Remove heat shield (6).

6

Remove screws (7) from clamping brackets (8).

 Installation: Replace the screws/bolts (7) and the clamps (8). Coat thread of screws (7) with heat-resistant lubricating paste.

 Bolt, exhaust gas recirculation line clamp to exhaust gas recirculation cooler

*BA14.20-N-1001-01K

Copper paste (article no. 3080)

*BR00.45-Z-1080-06A

7

Remove screws (9).

 Removal of the screws (9) is simplified by loosening them beforehand by means of hammer blows.

 Installation: Coat thread of screws/bolts (9) with heat-resistant lubricant.

 Bolt, exhaust gas recirculation line to exhaust manifold

*BA14.20-N-1002-01K

Copper paste (article no. 3080)

*BR00.45-Z-1080-06A

8

Remove exhaust gas recirculation line (10).

 Installation: Clean sealing surfaces on exhaust gas recirculation line (10), on exhaust manifold (11), and on exhaust gas recirculation cooler (12). Replace seal (13).

9

Install in the reverse order.

10

Perform engine test run.

 See information from body manufacturer.
Allow the engine to run at a higher engine speed.

11

Check exhaust gas recirculation line (10) for leak tightness.

 Visual inspection.

 Exhaust gas recirculation

Number

Designation

Engine 935.9

BA14.20-N-1001-01K

Bolt, exhaust gas recirculation line clamp to exhaust gas recirculation cooler

M8

Nm

25

 Exhaust gas recirculation

Number

Designation

Engine 935.9

BA14.20-N-1002-01K

Bolt, exhaust gas recirculation line to exhaust manifold

M8

Nm

25

Repair materials

Number

Designation

Order number

BR00.45-Z-1080-06A

Copper paste (article no. 3080)

Liqui Moly GmbH
Jerg-Wieland-Strasse 4
89081 Ulm-Lehr, Germany
www.liqui-moly.de