Remove/install exhaust gas recirculation bypass flap

AR14.20-S-7661PS

Remove/install exhaust gas recirculation bypass flap

20.09.2018

Engine

642 in model 470, 471

Modification notes

11.07.2018

Method extended

Operation steps 7, 9, 10

1

EGR bypass flap

2

Vacuum hose

3

Bypass switchover valve

4

Screw

5

Bolts

6

Exhaust gas recirculation line

7

Exhaust gas recirculation line

8

Bolts

1

EGR bypass flap

9

Exhaust gas recirculation fitting

10

Mixing chamber

11

Sealing ring

 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 avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Remove fan unit.

AR20.40-S-5050PS

 Installation: Only install upper engine cover after the leak test.

2

Remove vacuum hose (2) from vacuum cell.

3

Unhook bypass switchover valve (3) from bracket and place to one side.

4

Remove bolts (8).

 Bolt, exhaust gas recirculation line to mixing chamber

*BA14.20-N-1008-01PS

5

Remove screws (5).

 Screw, exhaust gas recirculation line to heat exchanger

*BA14.20-N-1002-01PS

6

Remove exhaust gas recirculation bypass flap (1) with exhaust gas recirculation lines (6, 7).

 Installation: Replace gaskets and O-rings.

 Assembly tool

*000589936300

7

Remove exhaust gas recirculation fitting (9) from mixer housing (10).

 Installation: Replace the sealing ring (11).

 Assembly tool

*000589936300

8

Seal openings with suitable stop plugs and protective covers.

 Set of protective covers

*001589019100

 Record plug

*129589009100

9

Unscrew screw (4).

If exhaust gas recirculation bypass flap (1) is replaced.

 Screw, exhaust gas recirculation line to changeover flap

*BA14.20-N-1003-01PS

10

Remove exhaust gas recirculation lines (6, 7) from exhaust gas recirculation bypass flap (1).

If exhaust gas recirculation bypass flap (1) is replaced.

 Installation: Replace O-ring at exhaust gas recirculation line (7) and seal at exhaust gas recirculation lines (6).

 Assembly tool

*000589936300

11

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

12

Perform engine test run and check exhaust gas recirculation bypass flap (1) in terms of leak tightness.

 Exhaust gas recirculation

Number

Designation

Engine 642 in model 470, 471

BA14.20-N-1002-01PS

Screw, exhaust gas recirculation line to heat exchanger

Nm

9

 Exhaust gas recirculation

Number

Designation

Engine 642 in model 470, 471

BA14.20-N-1003-01PS

Screw, exhaust gas recirculation line to changeover flap

Nm

9

 Exhaust gas recirculation

Number

Designation

Engine 642 in model 470, 471

BA14.20-N-1008-01PS

Bolt, exhaust gas recirculation line to mixing chamber

Nm

9