EGR Cooler: Service and Repair

Exhaust Gas Recirculation Cooler

The exhaust gas temperature sensor threads are coated. Do NOT lubricate with hot bolt paste and make sure to tighten it to specification, refer to=> [ Exhaust Temperature Control Overview ] Description and Operation. Otherwise the fitting could come loose and accidents could occur as a result.

Special tools, testers and auxiliary items required

• Ring Spanner 7-piece Set (3337)

• Wrench SW 13 (T10384)

• Tool Set 17 mm (T10395)

• Transport Lock (T10404)

• Engine Bung Set (VAS 6122)

• Hose Clip Pliers (VAS 6340)

• Drip Tray for VAS 6100 (VAS 6208)

• Hose Clip Pliers (VAS 6362)

Removing

• When installing, install all heat shield boots back in the same positions.

• Seal all openings with plugs from the engine bung set (VAS 6122).

• Various hose connections are secured.

• Replace the self-locking nuts.

• Before installing the oil supply line, fill the turbocharger with engine oil at the supply line connection.

- Follow the guidelines for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.

- Remove noise insulation.

- Drain the coolant. Refer to => [ Draining and Filling ] Procedures.

- Remove the front exhaust pipe with particulate filter. Refer to => [ Front Exhaust Pipe with Particulate Filter ] Front Exhaust Pipe with Particulate Filter.

- Remove the rear coolant pipe. Refer to => [ Rear Coolant Pipe ] Rear Coolant Pipe.

- Remove the EGR temperature sensor - 2 - from the Exhaust Gas Recirculation (EGR) pipe - 1 -.






- Remove the bolts - arrow A -.






- Remove the nut - arrow B -.

- Remove the EGR pipe - 1 - from the seal - 2 - for the intake tube - 3 -.

- Remove the EGR pipe - 1 - together with the sensor wire.

- Remove the bolts - 1 and 3 -.






- Remove the banjo bolts - 4 and 5 -.

- Remove the bolts - arrows - and then remove the heat shield.






- Loosen the fitting - 2 - and then remove the oil supply line - 1 - from the turbocharger - 3 -.






- Remove the oil line together with the turbocharger supports.

- Remove the nut - arrow - and remove the heat shield - 1 -.






- Place the drip tray for VAS 6100 (VAS 6208) under engine.






- Loosen the hose clamps to remove the coolant hoses - 1 and 3 - from the EGR cooler.

- Disconnect the connector - 2 -.

- Remove the bolts - arrows - and remove the EGR cooler.

Installing

Install in reverse order of removal. When doing this note the following:

• Replace gaskets, seals and self-locking nuts.

• The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.

• Secure hose connections with standard production clamps. Refer to the Parts Catalog.

• When installing, install all heat shield boots back in the same positions.

- Install the charge air hoses and screw type clamps. Refer to => [ Installing the Charge Air Hoses and Screw Type Clamps ] Service and Repair.

- Install the front exhaust pipe with particulate filter. Refer to => [ Front Exhaust Pipe with Particulate Filter ] Front Exhaust Pipe with Particulate Filter.

- Fill the coolant. Refer to => [ Draining and Filling ] Procedures.

Tightening Specifications