Remove/install exhaust gas recirculation pipe

AR14.20-D-1060SD

Remove/install exhaust gas recirculation pipe

17.11.15

Engine

642.896/898 in model 906

Exhaust collector pipe to EGR bypass flap

Shown on engine 642.896 in model 906.133

1

Exhaust pipe

6

Exhaust gas recirculation

13

Electrical connection

2

Exhaust collector pipe

7

Bracket

14

Bracket

3

Rear EGR line

10

Seal

B28/20

Diesel particulate filter differential pressure sensor

4

Clamp

11

Bracket

B85/3x1

Oxygen sensor electrical connection

5

Clamp

12

Pressure lines

Shown on engine 642.898 in model 906.133

12

Pressure lines

21

Pressure hoses

B85/3

Oxygen sensor

20

Electrical connection (ENGINE 642.898)

B19/18

Temperature sensor upstream of catalytic converter (engine 642.898)

B85/3x1

Oxygen sensor electrical connection

Shown on engine 642.898

5

Clamp

12

Pressure lines

15

Tensioning strap

16

Catalytic converter with diesel particulate filter

17

Clamp

18

Electrical line

19

NOx sensor (engine 642.898)

B19/19

Temperature sensor upstream of diesel particulate filter

 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

 

Remove/install

1

Remove exhaust gas recirculation (6)

AR14.20-D-1050SG

2

Remove catalytic converter exhaust pipe (1) to ATL

Engine 642.896/898 in model 906
with code XM0 (Facelift)

AR49.10-D-5529M

Engine 642.896/898 in model 906
except code XM0 (Facelift)

AR49.10-D-5529SG

3

Remove rear EGR line (3) on exhaust gas recirculation line (2)

 Installation: Install new seal (10).

 Bolt, exhaust gas recirculation line to exhaust collector pipe

*BA14.20-N-1018-01H

 Set of flexible head wrenches

*001589810900

4

Remove clamp (4) for rear EGR line (3) from holder

 Bolt, exhaust gas recirculation line to bracket

*BA14.20-N-1019-01H

 Set of flexible head wrenches

*001589810900

5

Remove bracket (7)

 Bolt, diesel particulate filter to cylinder head holder

*BA14.40-N-1014-01B

 Bolt, catalytic converter with diesel particulate filter to cylinder head bracket

*BA14.40-N-1008-01B

 Screw/bolt, bracket to cylinder head

*BA01.20-N-1003-01O

 Set of flexible head wrenches

*001589810900

6

Disconnect oxygen sensor electrical connections (B85/3x1) and expose electrical line

7

Disconnect electrical connection (20) of temperature sensor upstream of catalytic converter (B19/18) and expose electrical line

Engine 642.898 in model 906Exhaust collector pipe to EGR bypass flap

8

Remove bracket (14) on bracket (11)

Engine 642.896 in model 906Exhaust collector pipe to EGR bypass flap

 M61

*BA00.10-N-1002-04A

9

Disconnect electrical connection (13) from diesel particulate filter differential pressure sensor (B28/20)

Engine 642.896 in model 906Exhaust collector pipe to EGR bypass flap

10

Remove diesel particulate filter differential pressure sensor (B28/20) on holder (11)

Engine 642.896 in model 906Exhaust collector pipe to EGR bypass flap

 Do not disconnect pressure lines (12).

 Bolt, pressure differential sensor to bracket

*BA07.04-N-1005-01G

11

Remove pressure hoses (21) from the pressure lines (12)

Engine 642.898 in model 906Exhaust collector pipe to EGR bypass flap

 Installation: Check clamps for damage; replace if necessary.

12

Remove clamp (5) for rear EGR line (3) from holder

 Bolt, exhaust gas recirculation line to bracket

*BA14.20-N-1019-01H

 Set of flexible head wrenches

*001589810900

13

Remove clamp (17) from catalytic converter with diesel particulate filter (16)

 Engine 642.896 in model 906Bolt, clamp securing catalytic converter with diesel particulate filter to exhaust pipe

*BA14.40-N-1009-01B

 Engine 642.898 in model 906Bolt, diesel particulate filter clamp to exhaust pipe

*BA14.40-N-1016-01B

14

Remove tensioning strap (15) from catalytic converter with diesel particulate filter (16)

 Engine 642.896 in model 906Bolt, tensioning strap securing catalytic converter with diesel particulate filter to bracket

*BA14.40-N-1007-01B

 Engine 642.898 in model 906Bolt, diesel particulate filter tensioning strap to holder

*BA14.40-N-1013-01B

15

Expose electrical line of temperature sensor upstream of diesel particulate filter (B19/19)

16

Pry off catalytic converter with diesel particulate filter (16) and pull to the rear


Engine 642.898 in model 906
Exhaust collector pipe to EGR bypass flapHandle the CAT with diesel particulate filter (16) carefully.
Damage can occur otherwise on the temperature sensor upstream of diesel particulate filter (B19/19), NOx sensor (19) and pressure hoses (21).


Engine 642.896 in model 906
Exhaust collector pipe to EGR bypass flapHandle the CAT with diesel particulate filter (16) carefully.
Damage can occur otherwise to the electrical line (18), oxygen sensor (B85/3), temperature sensor upstream of diesel particulate filter (B19/19) and the pressure lines (12).

17

Turn rear EGR line (3) and remove

 Installation: Clean sealing surfaces on exhaust manifold (2).

If the rear EGR line (3) is reused.



Clean sealing surfaces on rear EGR line (3).

18

Install in the reverse order

 Danger !

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

19

Check leaktightness of exhaust system when engine is running

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

Number

Designation

8.8

10.9

BA00.10-N-1002-04A

M61

Nm

9

13

 Crankcase ventilation, cylinder head cover

Number

Designation

Engine 642

BA01.20-N-1003-01O

Screw/bolt, bracket to cylinder head

M612

Nm

9

 Sensors, transmitters

Number

Designation

Engine 642

BA07.04-N-1005-01G

Bolt, pressure differential sensor to bracket

Nm

8

 Exhaust gas recirculation

Number

Designation

Engine 642.8 in model 906

BA14.20-N-1018-01H

Bolt, exhaust gas recirculation line to exhaust collector pipe

Nm

9

 Exhaust gas recirculation

Number

Designation

Engine 642.8 in model 906

BA14.20-N-1019-01H

Bolt, exhaust gas recirculation line to bracket

Nm

9

 Diesel particulate filter

Number

Designation

Engine 642.896 in model 906

BA14.40-N-1007-01B

Bolt, tensioning strap securing catalytic converter with diesel particulate filter to bracket

Nm

25

 Diesel particulate filter

Number

Designation

Engine 642.896 in model 906

Engine 642.898 in model 906

BA14.40-N-1008-01B

Bolt, catalytic converter with diesel particulate filter to cylinder head bracket

Nm

23

23

 Diesel particulate filter

Number

Designation

Engine 642.896 in model 906

BA14.40-N-1009-01B

Bolt, clamp securing catalytic converter with diesel particulate filter to exhaust pipe

Nm

18

 Diesel particulate filter

Number

Designation

Engine 642.898 in model 906

BA14.40-N-1013-01B

Bolt, diesel particulate filter tensioning strap to holder

Nm

25

 Diesel particulate filter

Number

Designation

Engine 642.896 in model 906

Engine 642.898 in model 906

BA14.40-N-1014-01B

Bolt, diesel particulate filter to cylinder head holder

Nm

23

23

 Diesel particulate filter

Number

Designation

Engine 642.898 in model 906

BA14.40-N-1016-01B

Bolt, diesel particulate filter clamp to exhaust pipe

Nm

18