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MBE 900 EGR COOLER

EGRCooler Removal

Remove the EGRcooler as follows: ‪

PERSONAL INJURY

To avoid injury from scalding, drain the radiator when the engine and coolant are cool.

  1. Drain the coolant.

    NOTICE:

    No coolant must escape during disassembly of the coolant inlet line. ‪

    1. EGR Delivery Pipe Bolts ‪

    6. Heat Shield ‪

    2. EGR Delivery Pipe Gasket ‪

    7. Heat Shield Mounting bolts ‪

    3. EGR Delivery Pipe ‪

    8. EGR Exhaust Elbow ‪

    4. Bolts ‪

    9. EGR Exhaust Housing ‪

    5. Bolts ‪

    EGR Cooler Removal and Installation

  2. Remove the two bolts from the EGR delivery pipe. See Figure 44334 .
  3. Remove four bolts from the EGR cooler upper flange. See Figure 44334 .
  4. Remove EGR delivery pipe. See Figure 44334 .

    Note: The EGR cooler end gasket is a one piece gasket. Whenever the EGR delivery tube is removed, the EGR exhaust elbow must also be removed to replace the gasket. If the EGR exhaust elbow is removed the EGR delivery tube must be removed in order to replace the gasket.

  5. Remove three bolts from heat shield and remove shield. See Figure 44334 .
  6. Remove four bolts from the lower EGR cooler flange. Remove housing and elbow. See Figure 44334 .
  7. Remove elbow from housing and inspect seal rings. If damaged replace seal rings. See Figure 44334 .

    1. Coolant Inlet Tube ‪

    5. Hose Clamps ‪

    2. Coolant Return Tube ‪

    6. Bolts ‪

    3. Clamps ‪

    7. Coolant Return Tube Clamp ‪

    4. EGR Delivery Pipe ‪

    8. EGR Cooler ‪

    Coolant Inlet Line and Related Components

  8. Remove bolts from clamps securing coolant inlet tube to thermostat housing and air intake manifold. See Figure 44335 .
  9. Loosen two hose clamps from hose on coolant inlet tube.
  10. Remove coolant inlet tube and O-ring. Discard O-ring.
  11. Remove two bolts, hose and clamps securing EGRcoolant return tube to thermostat housing and EGR cooler. See Figure 44335 .
  12. Remove EGR coolant return tube and gasket. Discard gasket.
  13. Remove electrical plug connector from the EGR rotary valve. See Figure 44336 .
  14. Remove two bolts securing the EGR cooler. See Figure 44336 .

    Note: On MBE 904, 906, 924 and 926 engines, the EGR cooler is secured with two brackets with two hose clamps.

    1. EGR Rotary Valve Electrical Connector ‪

    4. EGR Cooler ‪

    2. EGR Rotary Valve ‪

    5. Clamps ‪

    3. Bolts ‪

    EGR Rotary Valve and Related Components

  15. Remove the hose clamps on the EGR cooler. See Figure 44336 .
  16. Remove the EGR cooler with the EGR rotary valve still attached. See Figure 44336 .
  17. If required, remove two EGR cooler lower support brackets by removing two bolts per bracket.
  18. Remove the EGR rotary valve from the EGR cooler by removing five nuts and gasket. Discard gasket. See Figure 44336 .

EGRCooler Installation

Install the EGR cooler as follows (see Figure 44336 for component location): ‪

  1. Install the EGR rotary valve and new gasket on the EGR cooler with five nuts. Tighten nuts to 31-35 Nm (23-26 lbft).
  2. If removed, install two lower EGR cooler support brackets and secure with two bolts per bracket. Tighten bolts to 60-66 Nm (44-49 lbft).
  3. Install the EGR cooler on lower support brackets.
  4. Secure EGR cooler with two bolts. Tighten bolts to 31-35 Nm (23-26 lbft).
  5. Install and tighten clamps on the EGR cooler.
  6. Install electrical plug connector to the rotary valve. See Figure 44336 .
  7. Inspect the coolant return hose for any damage. Replace hose if required. Install the coolant return tube in hose. Using a new gasket and two bolts secure to the thermostat housing. Tighten bolts to 31-35 Nm (23-26 lbft). See Figure 44335 .
  8. Tighten hose clamps on coolant hose.
  9. Install new seal ring on coolant inlet tube. See Figure 44335 .
  10. Install coolant inlet tube into hose and secure coolant inlet tube with two bolts at clamps. Tighten bolts to 31-35 Nm (23-26 lbft). See Figure 44335 .
  11. Install EGR exhaust elbow with seal rings in EGR exhaust housing and into end of exhaust manifold. See Figure 44334 .

    Note: The EGR cooler end gasket is a one piece gasket. Whenever the EGR delivery tube is removed, the EGR exhaust elbow must also be removed to replace the gasket. If the EGR exhaust elbow is removed the EGR delivery tube must be removed in order to replace the gasket.

  12. Using a new gasket, install the EGR exhaust housing using four bolts. Tighten bolts to 31-35 Nm (23-26 lbft). See Figure 44334 .
  13. Install heat shield using three mounting bolts. Tighten bolts to 12-14 Nm (9-10 lbft). See Figure 44334 .
  14. Loosely install EGR delivery pipe at upper cooler flange with four bolts. See Figure 44334 .
  15. Install the EGR delivery pipe using a new gasket and two bolts. Tighten bolts to 31-35 Nm (23-26 lbft). See Figure 44334 .
  16. Tighten EGR delivery pipe bolts at lower flange. Tighten bolts to 31-35 Nm (23-26 lbft). See Figure 44334 .
  17. Fill engine with fresh coolant to required levels.
Testing Engine for Leaks

Perform the following steps to test the engine for coolant leaks: ‪

  1. Check the coolant level and top off if required.
  2. Check for leaks with the engine running.
  3. If any leaks are observed shut engine down and make necessary repairs.