Remove/install high-pressure exhaust gas recirculation cooler · ar1420p7682mff · Mercedes-Benz WIS

AR14.20-P-7682MFF

Remove/install high-pressure exhaust gas recirculation cooler

06.03.2020

Engine

654 in model 118, 177, 247

Modification notes

16.01.2020

Document completely revised.

Remove/install high-pressure exhaust gas recirculation cooler

1	High pressure exhaust gas recirculation cooler
2	Bolts
3	Exhaust gas recirculation line
4	Electrical connector
5	Ball stud
6	Engine wiring harnesses
7	Screw
8	Vacuum lines
12	Bolts
13	Coolant hose
14	Electrical connector

P14.20-A010-05

9	Bolts
10	Bolts
11	Screw

P14.20-A016-06

14	Electrical connector
15	Bracket
16	Coupling flange
17	Cable duct

P14.20-A020-06

 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
 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
 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 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 air filter housing.		AR09.10-P-1150MFF
3	Remove engine charge air duct from exhaust gas turbocharger.		AR09.41-P-8622MFF
4	Remove ball stud (5).
5	Remove screw (7).
6	Release and disconnect electrical connector (4).
7	Remove vacuum lines (8).
8	Remove exhaust gas recirculation cooler bypass switchover valve from high-pressure exhaust gas recirculation cooler (1) and place to one side with lines connected.		AR14.20-P-7667MFF
		 Do not kink, crush or subject electric line to tension. Otherwise damage will occur.
9	Remove bolts (12) and bolts at high-pressure exhaust gas recirculation cooler (1).
10	Remove exhaust gas recirculation line (3).
11	Remove O-ring and seal from exhaust gas recirculation line (3).	 Assembly tool	*000589936300
12	Remove coolant hose (13) from high-pressure exhaust gas recirculation cooler (1).	 Hose clamp pliers	*454589003700
13	Remove bracket (15) from coupling flange (16).
14	Release cable duct (17) (arrow A) and place to one side.
15	Release and disconnect electrical connector (14).
16	Place engine wiring harnesses (6) to one side.
17	Remove screws (2).
18	Remove screw (11) .
19	Remove screws (9).
20	Remove screws (10).
21	Remove high-pressure exhaust gas recirculation cooler (1).	 The high-pressure exhaust gas recirculation cooler(1) is removed together with the high-pressure exhaust gas recirculation valve.
22	Remove seal from coolant line at exhaust gas recirculation valve.
23	Remove seal from high-pressure exhaust gas recirculation line at high-pressure exhaust gas recirculation valve.
	Clean
24	Clean all separation points.	Assembly cleaner	*BR00.45-Z-1028-04A
25	Seal all openings with suitable protective covers, grommets, stop plugs.	 Record plug	*129589009100
		 Set of plugs	*199589009800
		 Set of protective caps	*001589029100
		 Set of protective caps	*001589009100
	Install
26	Remove protective covers, plugs, stop plugs.	 Record plug	*129589009100
		 Set of plugs	*199589009800
		 Set of protective caps	*001589029100
		 Set of protective caps	*001589009100
27	Attach seal to coolant line at exhaust gas recirculation valve.	 Replace seal.
28	Attach seal to high-pressure exhaust gas recirculation line.	 Replace seal.
29	Install high-pressure exhaust gas recirculation cooler(1).	 The high-pressure exhaust gas recirculation cooler(1) is installed together with the high-pressure exhaust gas recirculation valve.
30	Attach O-ring and seal to exhaust gas recirculation line (3).	 Replace O-ring and seal.
		 Assembly tool	*000589936300
31	Install exhaust gas recirculation line (3) and position on high-pressure exhaust gas recirculation cooler (1).
32	Screw in screw/bolts (2, 11, 12).	Tighten screws of high-pressure exhaust gas recirculation cooler	AR14.20-P-0001-01MFF
		 Replace screw/bolts (2, 11, 12). Pay attention to different lengths of screws.
		 Bolt, exhaust gas recirculation valve to lifting eye	*BA14.20-P-1030-01Q
		 Bolt, exhaust gas recirculation cooler to charge air distributor	*BA14.20-P-1032-01Q
		 Bolt, exhaust gas recirculation line to charge air distributor	*BA14.20-P-1034-01Q
33	Slightly tighten screw/bolts (9, 10) by hand.	 Pay attention to different lengths of screws.
		 Replace bolts (9, 10).
34	Tighten screws (9).	 Bolt, coolant line to exhaust gas recirculation valve	*BA14.20-P-1027-01Q
35	Tighten bolts (10).	 Bolt, high pressure EGR line to high pressure exhaust gas recirculation valve	*BA14.20-P-1025-01Q
36	Clip engine wiring harnesses (6) into working area.
37	Connect and lock electrical connector (14).
38	Attach cable duct (17) to high-pressure exhaust gas recirculation valve and lock (arrow A).
39	Attach bracket (15) to coupling flange (16).
40	Attach coolant hose (13) to high-pressure exhaust gas recirculation cooler (1).	 Hose clamp pliers	*454589003700
41	Install exhaust gas recirculation cooler bypass switchover valve on high-pressure exhaust gas recirculation cooler (1).		AR14.20-P-7667MFF
42	Install vacuum lines (8).
43	Connect and lock electrical connector (4).
44	Screw in screw/bolt (7).	 M61	*BA00.10-P-1002-04A
45	Screw in ball stud (5).	 Ball stud on engine cover to high pressure exhaust gas recirculation valve	*BA01.10-P-1001-01D
46	Install engine charge air duct at exhaust gas turbocharger.		AR09.41-P-8622MFF
47	Install air filter housing.		AR09.10-P-1150MFF
		 Only install upper engine cover after the leak test.
48	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
49	Start engine and read out actual value of exhaust gas temperature upstream of diesel oxidation catalytic converter in CDI control unit (N3/9).
			AD00.00-P-2000-06MFA
50	Check activation of exhaust gas recirculation.	 Exhaust gas recirculation is active from an exhaust gas temperature of at least 155 °Cupstream of the diesel oxidation catalytic converter and in the idle to mid-partial load range.
51	Check high-pressure exhaust gas recirculation cooler (1) for leaks.
52	Switch off engine.
53	Install upper engine cover.		AR01.10-P-2405MFF
54	Read out fault memory and delete if necessary.
			AD00.00-P-2000-06MFA

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number	Designation		8.8	10.9
BA00.10-P-1002-04A	M61	Nm	9	13

 Engine cover

Number	Designation		Engine 654
BA01.10-P-1001-01D	Ball stud on engine cover to high pressure exhaust gas recirculation valve	Nm	4

 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-1027-01Q	Bolt, coolant line to exhaust gas recirculation valve	Stage 1	Nm	8
		Stage 2	°	60

 Exhaust gas recirculation

Number	Designation			Engine 654
BA14.20-P-1030-01Q	Bolt, exhaust gas recirculation valve to lifting eye	Stage 1	Nm	8
		Stage 2	°	60

 Exhaust gas recirculation

Number	Designation			Engine 654
BA14.20-P-1032-01Q	Bolt, exhaust gas recirculation cooler to charge air distributor	Stage 1	Nm	8
		Stage 2	°	60

 Exhaust gas recirculation

Number	Designation			Engine 654
BA14.20-P-1034-01Q	Bolt, exhaust gas recirculation line to charge air distributor	Stage 1	Nm	10
		Stage 2	°	60

000 589 93 63 00

Assembly tool

454 589 00 37 00

Hose clamp pliers

199 589 00 98 00

Set of plugs

001 589 00 91 00

Set of protective caps

129 589 00 91 00

Record plug

001 589 02 91 00

Set of protective caps

Repair materials

Number	Designation	Order number
BR00.45-Z-1028-04A	Assembly cleaner	A 000 986 56 01

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