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Removing and installing the EGR module

Removing and installing the EGR module

Additional jobs
Draining and topping up the coolant, see Maintenance Manual 58
Removing and installing the coolant manifold
Removing and installing the charge air manifold

(1) EGR module (3) Connecting pipe, EGR module - intake pipe
(2) Connecting manifold (4) Coolant manifold to EGR module

Technical data
EGR module mounting bolts M10x40-10.9 75 Nm
Connecting pipe mounting bolts M8x25-10.9 35 Nm
EGR positioning cylinder preload 1.25 ± 0.25 mm
EGR positioning cylinder mounting nuts M8 30 Nm
EGR positioning cylinder lock nut M8 22 Nm

Service products
Technical Vaseline 09.15014-0001

Important information

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WARNING
Component damage due to incorrectly tightened screw/bolt connections
If impact wrenches are used, these may only be used for pretightening to max. 50 % of the
specified tightening torque
Final tightening must always be performed manually using a torque wrench
Special tools
[1] 08.71000-3217 Dial gauge

Setting the EGR positioning cylinder in conjunction with:

Dial gauge holder

[2] 08.71092-0005 Dial gauge holder

Setting the EGR positioning cylinder in conjunction with:

Dial gauge

Removing the EGR module

Detaching the EGR module

Unscrew the mounting bolts (5) and (6)

Pull the EGR module off the unscrewed conduits (1) and (2)
Remove the seal (3) from the connecting pipe (4)
Clean the mating faces

Removing the EGR positioning cylinder

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Disconnect the electrical connection for the positioning cylinder (1)

Unscrew the mounting nuts (2) with washers (3)
Remove the (1) positioning cylinder

Installing the EGR module

Installing the EGR positioning cylinder

Push the positioning cylinder (1) onto the EGR cap (4)
Fit the washers (3)
Screw on the mounting nuts (2) and tighten to 30 Nm
Connect the electrical connection for the positioning cylinder (1)

Setting the EGR positioning cylinder

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Place Dial gauge holder(1) with Dial gauge(4) onto the lock-up valve housing
Place the measuring tip on the EGR positioning cylinder with a preload
Undo the lock nut (3)
Unscrew the cylinder rod (2) by several turns
Screw in the cylinder rod (2) until the pointer on the Dial gauge (4) no longer moves
Turn the cylinder rod (2) one turn further
The positioning cylinder preload must be 1.25 ± 0.25 mm
Tighten the lock nut (3) to 22 Nm

Mounting the EGR module

Apply Technical Vaseline on the unscrewed conduit (2) and insert it

Insert the unscrewed conduit (1) into the exhaust manifold
Position the EGR module with new seal (3) at the connecting pipe (4)
Screw in the mounting bolts (6) and tighten them by hand
Screw in the mounting bolts (5) and tighten them to 35 Nm
Tighten the mounting bolts (6) to 75 Nm

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