MBE 4000 EGRCONTROL VALVE, GAS OUTLET PIPE, AND GAS MIXER
The EGRcontrol valve controls the quantity of exhaust gas returning back to the intake manifold.
Removal of EGRControl Valve, Gas Outlet Pipe, and Gas Mixer
Remove the EGRcontrol valve, gas outlet pipe, and gas mixer as follows:
Remove the EGR control valve cover mounting bolts attached to the front lifter bracket and to the rear of the EGRvalve. See Figure
1. EGRControl Valve Cover Mounting Bolts
Removal of EGRControl Valve Cover
Loosen the wiring harness terminal from the back cover mounting bracket by punching the push-mount cable tie out of the drilled hole in the mounting bracket. Remove the two mounting bolts attaching the back cover bracket to the control valve. See Figure
. Remove back bracket.
1. EGRControl Valve Back Mounting Bracket
2. Push-Mount Cable Tie
Removing the Back Control Valve Cover Bracket
Remove the two bolts from gas outlet pipe attaching the pipe to the gas mixer. See Figure
1. Gas Outlet Pipe Flange
2. Gas Outlet Pipe Mounting Bracket
Removal of EGRGas Outlet Pipe
Remove the metal gasket.
Remove the three bolts that attach the gas outlet pipe mounting bracket to the intake manifold and to the outlet pipe. See Figure
Pull outlet pipe away from mixer and from the EGRcontrol valve, exposing the membrane in the control valve. See Figure
2. EGRTemperature Sensor
Removing the Symmetric Membrane on Gas Outlet Pipe Side
Pull the gas mixing pipe and metal gasket out of the air inlet pipe of mixer. See Figure
1. Intake Manifold
3. Gas Mixing Pipe
2. AIr Inlet Mixer
4. Metal Gasket
Removal of Gas Mixing Pipe
Remove the turbo boost/air temperature sensor attached to the gas mixer.
Remove the four bolts that attach the air intake pipe to the gas mixer. Remove the metal gasket as well. See Figure
1. Air Inlet Mixer Mounting Bolts (2 qty.)
3. Air Inlet Pipe
2. EGRGas Mixer
Removal of EGRGas Mixer
Remove the two bolts that attach the EGRgas mixer to the intake manifold. See Figure
. Pull gas mixer off of four long studs away from intake manifold.
Unscrew the four studs from intake manifold.
Remove the metal gasket.
Installation of EGRControl Valve, Gas Outlet Pipe, and Gas Mixer
Install the EGRcontrol valve and gas outlet pipe as follows:
Insert a symmetric membrane into the reed valve housing flange using industrial petroleum jelly. See Figure
Insert the EGRcontrol valve onto this membrane using petroleum jelly.
Install the back two bolts of the EGRcontrol valve (M8 x 90 mm). Install the front two bolts (those closest to the front lifter bracket) of the EGRcontrol valve (M8 x 40 mm). Torque all bolts to 25 Nm (19 lbft).
Using two bolts, install the back control valve bracket that holds the wiring harness terminal in place. Torque to 25 Nm (19 lbft).
Connect wiring harness terminal to valve connector.
Insert a second membrane into the right side of the EGRcontrol valve housing using industrial petroleum jelly.
Taking the EGRgas outlet pipe in hand, fit component manually onto symmetric membrane, using petroleum jelly.
Install the four gas mixer mounting studs into the intake manifold.
Install metal gasket over studs.
Fit gas mixer over mounting studs and push on as far as possible.
Install the gas mixing pipe into the air inlet pipe of mixer using a new metal gasket. See Figure
To avoid any engine damage, ensure that the gas passage of the mixing pipe is turned towards the intake manifold.
Due to its awkward shape, gas outlet pipe must be mounted to gas mixer before the gas mixer can be firmly attached to intake manifold.
Mount gas outlet pipe to gas mixer using a new metal gasket and two M8 x 16 mm bolts. Adjust gas mixer if necessary to accommodate the gas outlet pipe. Torque to 25 Nm (19 lbft).
Position support bracket in place for gas outlet pipe. Install bracket using three M8 x 16 mm bolts. Torque to 25 Nm (19 lbft).
Install the air inlet pipe to the gas mixer using four nuts. Torque to 50 Nm (37 lbft). See Figure
Install the turbo boost/air intake temperature sensor to the gas mixer.