Contents: Installation ⬇ Replacing the middle and rear…⬇ Removal and installation of exhaust…⬇ Removal and installation the EGR…⬇ Installation ⬇ Removal and installation exhaust gas…⬇ Assembly diagram of the exhaust gas…⬇
Remove the upper engine cover. Remove the charge air pipe to the right. Remove the intake manifold flap motor "V157". Remove the EGR valve "N18" with the EGR potentiometer "212" and the EGR regulator "V338". Disconnect the plug connector for the lambda probe "G39", the temperature sensor before and behind the particulate filter. Remove the temperature sensor in front of the particulate filter "G448". Unscrew the lambda probe "G39".
Unscrew the pressure line on the particulate filter. Remove the heat shield. Remove the particulate filter mounting bracket. Unscrew the exhaust gas pressure sensor 1 "G450". Remove the lower engine cover. Having released the axle suspension mounting beam, center it in the service position. Remove the propeller shaft housing from the engine. Unscrew the temperature sensor behind the particulate filter "G527" from the outlet pipe behind the particulate filter. Unscrew the pressure line "2" for the pressure sensor 1 for the outlet line "G450".
Unscrew the "arrow" screws on the particulate filter holder.
Important: The connection element at the front of the exhaust pipe must not be positioned at an angle greater than 10° - risk of damage.
Loosen the double clamp nuts. Unscrew the exhaust system spring hanger clamp. Remove the front section of the exhaust pipe with the particulate filter.
Installation
Installation is carried out in the reverse order of actions. In this case, the following instructions must be observed.
Important: Replace seals and self-locking nuts. All hose connections must be secured with appropriate hose clamps. Any cable clamps that were loosened during removal must be reattached in the same position during reinstallation. When installing the connecting hose with a push-in connection, ensure that the locking clamp "arrow" is engaged behind the retaining tabs "4". Align the exhaust system so that it is free of internal stress. After replacing the particulate filter, it is necessary to carry out the adaptation in the "Controlled functions" function of the VAS5051 vehicle diagnostics and measurements.
Replacing the middle and rear sections of the exhaust manifold
For separate replacement of the middle and rear parts of the exhaust pipe, respectively, a cutting point is designated on the connecting pipe, indicated on the surface of the pipe by a stamped recess. Cut the exhaust pipe at a right angle at the cut point "arrow 1" with a body saw. When installing, position the double clamp "4" on the side marks "arrow 2" and "arrow 3".
Install the double clamp so that the ends of the screws do not protrude through the bottom edge. Align the exhaust system so that it is free of internal stress. Tighten the double clamp screws evenly to a torque of 23 Nm. The screw connection faces right.
Removal and installation of exhaust gas recirculation system components for engines with the letter designations BNM, BNV
1 - Intake gas pipeline; 2 - O-ring seal, replace; 3 - Inlet pipe; 4 - Mechanical EGR valve, part of the intake manifold, can only be replaced as a set with the intake manifold; 5 - Throttle valve motor in the intake manifold "V157"; 6 - 10 Nm; 7 - From the charge air cooler; 8 - Exhaust manifold; 9 - Seal, replace; 10 - Radiator, exhaust gas recirculation system; 11 - 25 Nm; 12 - To the heating system heat exchanger; 13 - 25 Nm; 14 - 25 Nm; 15 - From the cylinder head
Removal and installation the EGR cooler for engines with the letter designations BNM, BNV
Remove the upper engine cover. Remove the upper boost air pipe "1" with connecting hose "2" "arrows".
Remove the intake manifold flap motor "V157". Place a catch basin under the motor. After securing the coolant hoses with clamps "MP 7-602 (3094)", disconnect the hoses from the radiator. Unscrew the EGR cooler from the mechanical EGR valve. Unscrew the EGR cooler from the intake manifold. After unscrewing the EGR cooler from the exhaust manifold, remove the cooler.
Installation
Installation is carried out in the reverse order of actions. In this case, the following instructions must be observed.
Important: Replace seals and self-locking nuts. All hose connections must be secured with appropriate hose clamps. Pour in coolant.
Removal and installation exhaust gas recirculation system components for engines with the letter designation BMS
1 - Seal, replace, observe the assembly position; 2 - Intake gas pipeline; 3 - O-ring, replace; 4 - Fitting; 5 - Intake manifold flap motor "V157". After the engine is turned off, the intake manifold flap closes for approximately 3 seconds and then opens again. This reduces the shock when turning off; 6 - Holder; 7 - From the charge air cooler; 8-10 Nm; 9 - exhaust gas recirculation valve "N18" with EGR potentiometer "G212" and EGR actuator "V338"; before installation, check the sealing surfaces on the intake manifold for contamination and clean if necessary; 10 - Seal, replace; 11 - Radiator, exhaust gas recirculation system; 12 - 22 Nm; 13 - 22 Nm
Important: After replacement, the new part should be adjusted in the following manner: turn the ignition on and off; then wait 1 minute for the control units to run out of inertia, start the engine and let it run for at least 12 minutes at idle speed, it is impossible to clear the VAS 5051 fault memory so that no fault is loaded into the memory. In case of a loaded fault, the contents of the fault memory should be reset and the entire procedure should be repeated.
Assembly diagram of the exhaust gas recirculation cooling system for an engine with the letter designation BMS
1 - Coolant hose, connected to the pipe leading to the thermostat, coolant hose installation diagram; 2 - Seal, replace; 3 - 22 Nm; 4 - Connecting pipe; 5 - From the exhaust manifold; 6 - 25 Nm, replace; 7 - To the exhaust gas recirculation system valve branch pipe "N18" with the exhaust gas recirculation system potentiometer "G212" and the exhaust gas recirculation system regulator "V338"; 8 - Radiator, exhaust gas recirculation system; 9 - 10 Nm; 10 - Coolant hose from the heating system heat exchanger