Remove/install high-pressure exhaust gas recirculation valve

AR14.20-S-7684EA

Remove/install high-pressure exhaust gas recirculation valve

25.06.2019

Engine

654.9 in model 447

1

High pressure exhaust gas recirculation valve

2

High-pressure exhaust gas recirculation cooler

3

Electrical connector

4

Bracket

Shown with engine removed

1

High pressure exhaust gas recirculation valve

5

Bolts

6

Coolant line

7

Bolts

8

High pressure exhaust gas recirculation line

9

Pressure sensor

10

Bolts

11

Screw

12

Screw

Shown with engine removed

1

High pressure exhaust gas recirculation valve

2

High-pressure exhaust gas recirculation cooler

11

Screw

13

Bolts

 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

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A



Remove

1

Switch off ignition and store transmitter key outside of transmission range (min. 2  m).

2

Remove diesel oxidation catalytic converter.

AR49.20-S-0104EA

3

Drain off coolant.

AR20.00-S-1142E

4

Unscrew screws at bracket (4) and place bracket (4) with connected lines to the side.

5

Release and disconnect electrical connection (3).

6

Unscrew screws (5) of coolant line (6) at high-pressure exhaust gas recirculation valve (1).

7

Remove screws (7) of high-pressure exhaust gas recirculation line (8) at high-pressure exhaust gas recirculation valve (1).

8

Release cable duct, set down at top and secure with a cable tie.

AR15.18-S-0004-01EA

 Record plug

*129589009100

9

Unscrew screws (13).

10

Remove screws (11, 12).

11

Release high-pressure exhaust gas recirculation valve (1) from high-pressure exhaust gas recirculation cooler (2) and remove.

12

Remove screws (10) and remove pressure sensor (9) with housing at high-pressure exhaust gas recirculation valve (1).

If high-pressure exhaust gas recirculation valve (1) will be replaced.

13

Remove seal at housing of pressure sensor (9).

If high-pressure exhaust gas recirculation valve (1) will be replaced.

14

Remove seal between high-pressure exhaust gas recirculation valve (1) and high-pressure exhaust gas recirculation cooler (2).

15

Remove seal at coolant line (6).

16

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



Clean

17

Clean separating points of coolant line (6).

18

Clean separating points of high-pressure exhaust gas recirculation line (8).

19

Clean separating points of housing of pressure sensor (9).

If high-pressure exhaust gas recirculation valve (1) will be replaced.

20

Cover all separating points with suitable protective covers.

 Set of protective covers

*001589039100

 Set of protective caps

*001589009100



Install

21

Remove all installed protective covers.

22

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

23

Install new seal at coolant line (6).

24

Install new seal between high-pressure exhaust gas recirculation valve (1) and high-pressure exhaust gas recirculation cooler (2).

25

Install new seal at housing of pressure sensor (9).

If high-pressure exhaust gas recirculation valve (1) was replaced.

26

Position pressure sensor (9) with housing at high-pressure exhaust gas recirculation valve (1) and screw on with new screws (10).

If high-pressure exhaust gas recirculation valve (1) was replaced.

 Bolt, pressure sensor housing to high pressure exhaust gas recirculation valve

*BA14.20-N-1020-01EA

27

Position high-pressure exhaust gas recirculation valve (1) and screw on with new screws (11).

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

*BA14.20-N-1012-01EA

28

Screw in the new screw (12).

 Bolt, high pressure exhaust gas recirculation valve to high pressure exhaust gas recirculation cooler

*BA14.20-N-1009-01EA

29

Screw on high-pressure exhaust gas recirculation cooler (2) with new screws (13) at high-pressure exhaust gas recirculation valve (1).

 Bolt, high pressure exhaust gas recirculation valve to high pressure exhaust gas recirculation cooler

*BA14.20-N-1009-01EA

30

Fasten cable duct.

AR15.18-S-0004-01EA

 Use new bolts.

 Bolt, bracket for electrical lines to high pressure-exhaust gas recirculation valve/high pressure exhaust gas recirculation cooler

*BA14.20-N-1018-01EA

31

Screw on high-pressure exhaust gas recirculation line (8) with new screws (7) at high-pressure exhaust gas recirculation valve (1).

 Bolt, high pressure EGR line to high pressure exhaust gas recirculation valve

*BA14.20-N-1006-01EA

32

Screw on coolant line (6) with new screws (5) at high-pressure exhaust gas recirculation valve (1).

 Bolt, coolant line to high pressure exhaust gas recirculation valve

*BA14.20-N-1004-01EA

33

Connect electrical connector (3).

34

Position bracket (4) and screw on with screws.

35

Fill in coolant.

AR20.00-S-1142E

36

Install diesel oxidation catalytic converter.

AR49.20-S-0104EA

37

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

38

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.

39

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-1004-01EA

Bolt, coolant line to high pressure exhaust gas recirculation valve

Nm

10

 Exhaust gas recirculation

Number

Designation

Engine 654.9 in model 447

BA14.20-N-1006-01EA

Bolt, high pressure EGR line to high pressure exhaust gas recirculation valve

Nm

10

 Exhaust gas recirculation

Number

Designation

Engine 654.9 in model 447

BA14.20-N-1009-01EA

Bolt, high pressure exhaust gas recirculation valve to high pressure exhaust gas recirculation cooler

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

 Exhaust gas recirculation

Number

Designation

Engine 654.9 in model 447

BA14.20-N-1018-01EA

Bolt, bracket for electrical lines to high pressure-exhaust gas recirculation valve/high pressure exhaust gas recirculation cooler

Nm

8

 Exhaust gas recirculation

Number

Designation

Engine 654.9 in model 447

BA14.20-N-1020-01EA

Bolt, pressure sensor housing to high pressure exhaust gas recirculation valve

Nm

10