Remove/install high-pressure exhaust gas recirculation cooler

AR14.20-S-7682EA

Remove/install high-pressure exhaust gas recirculation cooler

25.06.2019

Engine

654.9 in model 447

Shown with engine removed

1

High pressure exhaust gas recirculation cooler

5

Coolant hose

2

Screw

6

Screw

3

Exhaust gas recirculation line

7

High pressure exhaust gas recirculation valve

4

Seal

8

Seal

 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

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-P-5000-01A



Remove

1

Remove high-pressure exhaust gas recirculation valve (7) at high-pressure exhaust gas recirculation cooler (1) and crankcase.

AR14.20-S-7684EA

 Do not remove coolant line and high-pressure exhaust gas recirculation line from high-pressure exhaust gas recirculation valve (7).

2

Remove screws (2).

3

Remove coolant hose (5) at high-pressure exhaust gas recirculation cooler (1) and collect escaping coolant.

 Hose clamp pliers

*454589003700

4

Remove screw/bolts (6).

5

Guide out high-pressure exhaust gas recirculation cooler (1) between exhaust gas recirculation line (3) and high-pressure exhaust gas recirculation valve (7) and remove.

6

Remove seal (4) at exhaust gas recirculation line (3).

7

Remove seal (8) at high-pressure exhaust gas recirculation cooler (1).



Clean

8

Clean separating points of exhaust gas recirculation line (3).

9

Clean separating points of high-pressure exhaust gas recirculation cooler (1) to high-pressure exhaust gas recirculation valve (7).

10

Cover all separating points with suitable protective covers.

 Set of protective covers

*001589039100

 Set of protective caps

*001589009100



Install

11

Remove all installed protective covers.

12

Install new seal (8) at high-pressure exhaust gas recirculation cooler (1).

13

Install new seal (4) at exhaust gas recirculation line (3).

14

Position high-pressure exhaust gas recirculation cooler (1) between exhaust gas recirculation line (3) and high-pressure exhaust gas recirculation valve (7) and slightly tighten new screws (6) by hand.

15

Install coolant hose (5) at high-pressure exhaust gas recirculation cooler (1).

 Hose clamp pliers

*454589003700

16

Install high-pressure exhaust gas recirculation valve (7) at high-pressure exhaust gas recirculation cooler (1) and crankcase.

AR14.20-S-7684EA

 Do not yet install air intake pipe.

17

Tighten screws/bolts (6).

 Bolt, high pressure exhaust gas recirculation cooler to lifting eye/crankcase

*BA14.20-N-1012-01EA

18

Slightly finger-tighten exhaust gas recirculation line (3) with new screws (2) at high-pressure exhaust gas recirculation cooler (1) and tighten.

 Bolt, high pressure exhaust gas recirculation line to high pressure exhaust gas recirculation cooler/mixer housing

*BA14.20-N-1007-01EA

19

Install air intake pipe.

AR09.10-S-8131EA

20

Read out actual value of exhaust gas temperature upstream of diesel oxidation catalytic converter in control unit.



AD00.00-S-2000-04E

 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

21

Perform engine test run until the activation of the exhaust gas recirculation is reached.

 Exhaust gas recirculation is active from an exhaust gas temperature of at least 155 °C upstream of the diesel oxidation catalytic converter and in the idle to mid-partial load range.

22

Read out and delete fault memory.



AD00.00-S-2000-04E

 Exhaust gas recirculation

Number

Designation

Engine 654.9 in model 447

BA14.20-N-1007-01EA

Bolt, high pressure exhaust gas recirculation line to high pressure exhaust gas recirculation cooler/mixer housing

Nm

10

 Exhaust gas recirculation

Number

Designation

Engine 654.9 in model 447

BA14.20-N-1012-01EA

Bolt, high pressure exhaust gas recirculation cooler to lifting eye/crankcase

Nm

10