Warning: When working on the Common Rail system, wait for one minute after switching off the engine. The system reduces the pressure automatically.

Transcription

1 Page 1 of 6 Replace exhaust gas recirculation valve J Warning: When working on the Common Rail system, wait for one minute after switching off the engine. The system reduces the pressure automatically. Important: When working on the fuel system, pay strict attention to cleanliness as even the smallest particle of dirt may lead to malfunctions in engine operation or the fuel system. Seal opened fuel connections with suitable closure plugs 1). Closure plugs are intended for single use. Remove 1. Open bonnet 2. Remove battery support. 3. Raise vehicle by its full height 4. Place collecting basin underneath. 5. Drain coolant Open drain bolt on radiator (1) Collect coolant Close drain bolt 6. Lower vehicle by its full height 7. Remove bulkhead closing part 8. Remove engine cover 9. Disconnect exhaust gas return wiring harness plug 10. Detach charge air pipe (1) from intake manifold Unscrew 3x bolts (2) Detach from bracket (3)

2 Page 2 of 6 Unscrew bolt 11. Remove throttle valve housing (1) Note: Applies to vehicles with the Z13 DTH engine. Detach vacuum line (2) from solenoid valve Unscrew 3 bolts 12. Remove brake force amplifier vacuum line (1) Disconnect quick-release fitting 13. Disconnect vacuum line (2)

3 Page 3 of Detach 2x coolant hose for heating (1) from coolant hose Undo 2 clamps 15. Remove coolant hose (1) from thermostat housing Release clamp Remove from bracket

4 Page 4 of Detach wiring harness bracket (1) Unscrew bolt (2) 17. Remove exhaust gas recirculation valve (1) Detach metal tube for exhaust gas recirculation from intake manifold Release clamp (2) Detach bracket for exhaust gas recirculation valve from cylinder block Unscrew bolt (3)

5 Page 5 of 6 Unscrew 2x bolts Remove valve and exhaust gas recirculation cooler assembly 18. Detach exhaust gas recirculation valve (1) from exhaust gas recirculation cooler (2) Detach expansion tank coolant hose from exhaust gas recirculation valve Release clamp Detach coolant hose, exhaust gas recirculation cooler to the coolant pipe Undo 2 clamps Unscrew 3 bolts Detach coolant pipe from exhaust gas recirculation valve Unscrew bolt Install 19. Clean sealing surface 20. Attach exhaust gas recirculation valve to exhaust gas recirculation cooler Attach coolant pipe to exhaust gas recirculation valve Tighten bolt

6 Page 6 of 6 Insert new gasket Tighten 3x bolt 25 Nm Attach coolant hose, exhaust gas recirculation cooler to the coolant pipe Attach 2x clamps Attach expansion tank coolant hose to radiator Fasten clamp 21. Install exhaust gas recirculation valve Use new seal Tighten 2x bolt 22 Nm 22. Attach exhaust gas return valve bracket to cylinder block Tighten bolt 22 Nm 23. Install wiring harness bracket Tighten bolt 25 Nm 24. Attach exhaust gas recirculation pipe to intake manifold Tighten clamp 25. Attach coolant hose to thermostat housing. Fasten clamp Mount in bracket 26. Attach 2x coolant hose for heating to coolant pipe Attach 2x clamps 27. Attach throttle valve housing Note: Applies to vehicles with Z13DTH engine. Tighten 3x bolt 8 Nm Attach vacuum line to solenoid valve 28. Fit charge air pipe at intake manifold Replace seal Tighten 3x bolts Attach to bracket Tighten bolt 29. Fit brake force amplifier vacuum line Connect quick release fitting 30. Connect exhaust gas return wiring harness plug 31. Install engine cover 32. Install bulkhead closing part 33. Connect battery Attach ground connection to ground terminal Tighten nut 34. Top up coolant or ensure correct quantity is present. 35. Program volatile memories 36. Close bonnet 1) ; protective caps are available in the parts catalogue