Remove/install exhaust gas recirculation cooler

AR14.20-P-7665GP

Remove/install exhaust gas recirculation cooler

18.12.12

ENGINE

642.884 in MODEL 461.305/333/340/343/392

1

Exhaust gas recirculation cooler

2

Coolant hoses

3

Screw/bolts

4

Screw/bolts

6

Screw/bolts

5

Vacuum line

8

Coolant hose

9

Coolant hose

10

Exhaust line

11

Electrical line

Y27/9

Exhaust gas recirculation positioner

13

Screw/bolts

14

Exhaust pipe

15

Nuts

16

Cover panel

 

Remove/install

 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 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

 Danger !

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

1

Open engine hood and raise to vertical position

AR88.40-P-1000GG

2

Remove air filter housing

AR09.10-P-1150GP

3

Unscrew nuts (15) and remove cover panel (16)

4

Remove screw/bolts (13) and detach exhaust pipe (14) on EGR bypass flap (changeover flap)

 Installation: Replace seal.

 Bolt, AGR pipe to changeover flap

*BA14.20-P-1007-01G

5

Drain and collect coolant from radiator

AR20.00-P-1142GX



Notes on coolant

AH20.00-N-2080-01A

6

Detach vacuum line (5) on vacuum adjuster for EGR bypass flap (changeover flap)

7

Disconnect electrical line (11) on coolant temperature sensor

8

Detach coolant hose (8) on EGR bypass flap (changeover flap)

 Installation: Check clamp; replace if necessary.

9

Disconnect electrical line on exhaust gas recirculation positioner (Y27/9)

10

Detach coolant hose (9) from exhaust gas recirculation positioner (Y27/9)

 Installation: Check clamp; replace if necessary.

11

Remove exhaust line (10)

 Bolt, exhaust line to AGR valve housing/mixing chamber

*BA14.20-P-1006-01G

12

Remove screw/bolts (3, 4)

 Bolt, changeover flap to holder

*BA14.20-P-1010-01G

 Bolt, AGR valve housing to holder

*BA14.20-P-1011-01G

13

Remove exhaust gas recirculation cooler (1) upwards

 Installation: Insert exhaust gas recirculation cooler (1) together with screw/bolts (3).

14

Detach coolant hoses (2) on exhaust gas recirculation cooler (1)

Only when replacing the exhaust gas recirculation cooler (1).

 Installation: Check clamps; replace if necessary.

15

Remove screw/bolts (6) and remove exhaust gas recirculation cooler (1)

Only when replacing the exhaust gas recirculation cooler (1).

 Installation: Replace gaskets.

 Bolt, heat exchanger to changeover flap

*BA14.20-P-1008-01G

 Bolt, heat exchanger to AGR valve housing

*BA14.20-P-1009-01G

16

Install in the reverse order

 Exhaust gas recirculation

Number

Designation

ENGINE 642.884

BA14.20-P-1009-01G

Bolt, heat exchanger to AGR valve housing

Nm

15

 Exhaust gas recirculation

Number

Designation

ENGINE 642.884

BA14.20-P-1007-01G

Bolt, AGR pipe to changeover flap

Nm

13

 Exhaust gas recirculation

Number

Designation

ENGINE 642.884

BA14.20-P-1011-01G

Bolt, AGR valve housing to holder

Nm

20

 Exhaust gas recirculation

Number

Designation

ENGINE 642.884

BA14.20-P-1008-01G

Bolt, heat exchanger to changeover flap

Nm

15

 Exhaust gas recirculation

Number

Designation

ENGINE 642.884

BA14.20-P-1006-01G

Bolt, exhaust line to AGR valve housing/mixing chamber

Nm

9

 Exhaust gas recirculation

Number

Designation

ENGINE 642.884

BA14.20-P-1010-01G

Bolt, changeover flap to holder

Nm

20