Remove/install exhaust gas recirculation cooler

AR14.20-P-7665OLD

Remove/install exhaust gas recirculation cooler

09.06.2016

Engine

651 in model 205, 253

1

Coolant hoses

5

Bolts

2

Screw

6

Bracket

3

Screw

7

Bolts

4

Ball stud

8

Sealing ring

 Danger !

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

 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



Notes on coolant

AH20.00-N-2080-01A

 

Remove/install

1

Remove vacuum reservoir

AR07.09-P-0001OLD

2

Clamp off coolant hoses (1) on exhaust gas recirculation cooler using a clamp

 Clamp

*000589403700

3

Detach coolant hoses (1) on exhaust gas recirculation cooler

4

Check condition of coolant hose (1) and clamps, replace if necessary

5

Remove screw/bolt (2) for guide tube on holder

 Bolt for oil dipstick guide tube fastening

*BA18.40-P-1002-01O

6

Remove screw/bolt (3) and ball stud (4) on exhaust gas recirculation cooler

 Bolt, exhaust heat exchanger support to exhaust heat exchanger

*BA14.20-P-1016-01K

 Bolt, support brace for vacuum reservoir and exhaust heat exchanger to Y-support brace

*BA14.20-P-1006-01K

7

Detach fuel filter with attached fuel lines and place to one side



AP47.20-P-0780EWD

8

Remove screw/bolts (5) and bracket (6)

 Bolt, exhaust heat exchanger to valve housing

*BA14.20-P-1001-01K

9

Remove screw/bolts (7) and exhaust gas recirculation cooler

 Use magnetic rod for better removal of the screw/bolts (7).

 Installation: Replace sealing ring (8).

 Bolt, exhaust heat exchanger to valve housing

*BA14.20-P-1001-01K

10

Install in the reverse order



Check

11

Check coolant level and correct if necessary

 Coolant mixing ratio

*BF20.00-P-1001-04A

12

Check engine cooling system for leaktightness

AR20.00-P-1010LW

 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

13

Carry out an engine test run and check exhaust recycle plant for leaktightness

 Exhaust gas recirculation

Number

Designation

Engine 651

BA14.20-P-1001-01K

Bolt, exhaust heat exchanger to valve housing

Nm

9

 Exhaust gas recirculation

Number

Designation

Engine 651

BA14.20-P-1006-01K

Bolt, support brace for vacuum reservoir and exhaust heat exchanger to Y-support brace

Nm

9

 Exhaust gas recirculation

Number

Designation

Engine 651

BA14.20-P-1016-01K

Bolt, exhaust heat exchanger support to exhaust heat exchanger

Nm

9

 Oil level sensor, oil pressure sensor

Number

Designation

Engine 651

BA18.40-P-1002-01O

Bolt for oil dipstick guide tube fastening

Nm

9

 Coolant mixing ratio

Number

Designation

Engine all

BF20.00-P-1001-04A

Coolant mixing ratio

Antifreeze/water

Up to -37°C

%

50/50

As of -38 °C

%

55/45

Sheet

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-00A

Sheet

BB00.40-P-0326-00A