Remove/install exhaust gas recirculation cooler

AR14.20-S-7665EF

Remove/install exhaust gas recirculation cooler

27.05.2020

Model

447 with engine 622.9

Modification notes

26.05.2020

Work procedure revised.

The whole document

1

Bracket

4

Screw

7

Screw

2

Bolts

5

Hose

8

Intake air duct

3

Bracket

6

Screw

9

Hose

10

Electrical connector

13

Clip

16

Bolts

11

Nuts

14

Heat shield

17

Electrical connectors

12

Exhaust pipe

15

Heat shield

18

Exhaust gas recirculation cooler

19

Screw

Y27/22

Low-pressure exhaust gas recirculation actuator

 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 the vehicle manufacturer.

AS00.00-Z-0010-01A

 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

 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

 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 avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

 

Remove/install

1

Remove engine charge air duct from exhaust gas turbocharger.

AR09.41-S-8622EF

2

Remove boost pressure control pressure transducer and place to one side.

AR07.17-S-7002EF

 The connections are not disconnected.

3

Remove bracket (1).

 To do this, remove screws (2).

4

Remove hose (9) from oil separator and from holder (3).

 Installation: Check cable ties for damage.

If damage is present,



Replace damaged cable ties.

5

Remove bracket (3).

 For this purpose, remove bolts (4).

6

Remove hose (5).

 Installation: Check clamp on hose (5) for damage.

 Hose clamp pliers

*454589003700

If damage is present,



Replace clamp on hose (5).

7

Remove screw (6).

 M6

*BA00.10-N-1002-01A

8

Remove screw (7).

9

Remove intake air duct (8).

10

Raise vehicle.

AR00.60-S-1000E

11

Remove nuts (11).

 Nut, exhaust pipe to diesel particulate filter

*BA49.10-N-1001-02E

12

Disconnect electrical connector (10).

13

Remove electrical wiring harness of exhaust gas flap.

14

Remove exhaust pipe (12).

 To do this, open clamp (13) and unhook exhaust pipe (12) from exhaust rubber.

 Installation: Replace seal.
Check clamp (13) for damage.

 Clamp, exhaust pipe to center muffler

*BA49.10-N-1005-02E

If damage is present,



Replace clamp (13).

15

Release heat shield (14).

 To do this, unscrew screws.

16

Remove heat shield (15).

 To do this, unscrew screws.

17

Remove bolts (16).

 Bolt, exhaust gas recirculation cooler exhaust pipe to diesel particulate filter

*BA14.20-N-1001-01N

18

Disconnect electrical connectors (17).

19

Remove exhaust gas recirculation cooler (18) with low-pressure exhaust gas recirculation actuator (Y27/22).

AR14.20-S-7662-03EF

 Bolt, exhaust gas recirculation cooler to bracket

*BA14.20-N-1002-01N

 Bolt, low-pressure exhaust gas recirculation actuator to bracket

*BA14.20-N-1003-01N

 Clamp

*000589403700

20

Remove exhaust gas recirculation cooler (18).

 Proceed by first removing the screws (19).

 Installation: Replace seals.

21

Modify exhaust gas recirculation temperature sensor.

Only when replacing the exhaust gas recirculation cooler (18).

AR07.04-S-0013EF

22

Install in the reverse order.

 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

23

Purge engine cooling system.

AR20.00-S-1142-06E



Service Information: Coolant

SI20.00-S-0001B



Check

24

Check engine cooling system for leak tightness.

AR20.00-S-1010E

 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

25

Check leak tightness in area of exhaust gas recirculation cooler (18) with low-pressure exhaust gas recirculation actuator (Y27/22) while engine is running.

 Visual inspection only.

 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 622 in model 447

BA14.20-N-1001-01N

Bolt, exhaust gas recirculation cooler exhaust pipe to diesel particulate filter

Nm

25

 Exhaust gas recirculation

Number

Designation

Engine 622 in model 447

BA14.20-N-1002-01N

Bolt, exhaust gas recirculation cooler to bracket

Nm

25

 Exhaust gas recirculation

Number

Designation

Engine 622 in model 447

BA14.20-N-1003-01N

Bolt, low-pressure exhaust gas recirculation actuator to bracket

Nm

25

 Exhaust system

Number

Designation

Engine 622 in model 447

BA49.10-N-1001-02E

Nut, exhaust pipe to diesel particulate filter

Nm

8

 Exhaust system

Number

Designation

Engine 622 in model 447

BA49.10-N-1005-02E

Clamp, exhaust pipe to center muffler

Nm

35