6057611x Eng

25/04/2017 14 7611 Checking exhaust gas recirculation
Page 1
14 7611 Checking exhaust gas recirculation
Work no.
And times:
The working texts and working values or standard texts
14 7611
P14 5141 59
Connection diagram Digital tester without adapter, arrangement of the components
Digital testing device (001) and
Pulse generator (021). . . . . . . . . . . . . . . . . . . . . . . An .
Battery voltage. . . . . . . . . . . . . . . . . . . . . . .
Protection between sockets 1 and 5.
Engine on coolant temperature . . . . . . . . . . . . . 60 80 C.
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RA 14.1621 7611 / 1
Page 2
Functional check. . . . . . . . . . . . . . . . . . . . . . . Carry out. Motor 605.911 section a

Motor 606.910 section b
If no error is detected,
Corresponding component check according to
Perform the test program.
Special tools
603 589 00 21 00 201 589 13 21 00 201 589 00 99 00
617 589 09 21 00
Commercial tools and / or test equipment (see operating manual)
designation Eg company, order no.
Multimeter Sun, DMM 5
Fluke, 23, DB, 83, 88
ITT Metrix MX 47, 50, 51, 52
Application without adapter
Digital test equipment AVL, Diesel ™ tester 873
Bosch, ETD 019.02
Sun, DIT 9100
Application with adapter
Digital test equipment Bosch, MOT 103, 002.02, 150, 250, 401. *** "
Motordiagnose Test device Hermann D960, D980
Bear DEACE
Y Distribution MB Parts No. 117 078 01 45
RA 14.1621 7611 / 2
Page 3
Motor 605.911
Functional diagram Exhaust gas supply Motor 605.911 with mechanical gearbox
P14 5139 57
4/5 Air filter B11 / 8 Temperature sensor coolant, afterglow
5 flywheel L3 Wheel Bearing
10 Injection pump N8 / 2 Control unit ARA
12/1 Vacuum can stop N14 Preheating relay
12/3 Pressure receptacle PLA N22 Control and operating unit
24 Accelerator pedal Automatic climate control (KLA)
61/1 Ballast with filter N37 Control unit ARF
64/1 Thermoventil 30 C closes S27 / 6 Microswitch compressor shutdown / ARF
65 Vacuum control valve Y22 / 3 Positioning solenoid ARA
100 Intake manifold Y27 Changeover valve ARF
101 Exhaust gas return valve Y28 Changeover valve Pressure control valve
102 Vacuum box pressure control valve
104 Vacuum pump A Ventilation to the vehicle interior
107 Exhaust manifold B Key lock
109 Pressure control valve housing C
E To the brake
RA 14.1621 7611 / 3
Page 4
Functional diagram Exhaust gas return Motor 605.911 with automatic transmission
P14 5140 57
4/5 Air filter B11 / 8 Temperature sensor coolant, afterglow
5 flywheel L3 Wheel Bearing
10 Injection pump N14 Preheating relay
12/1 Vacuum can stop N22 Control and operating unit
12/3 Pressure receptacle PLA Automatic climate control (KLA)
24 Accelerator pedal N37 Control unit ARF
61/1 Ballast with filter S27 / 6 Microswitch compressor shutdown / ARF
64/1 Thermoventil 30 C closes Y27 Changeover valve ARF
65 Vacuum control valve Y28 Changeover valve Pressure control valve
100 Suction pipe
101 Exhaust gas return valve A Ventilation to the vehicle interior
102 Vacuum box pressure control valve B Key lock
104 Vacuum pump C
106 Negative pressure modulating pressure D For modulating pressure
107 Exhaust manifold E To the brake
109 Pressure control valve housing
123 Pressure transducer Pressure and vacuum connections
Pressure transducer
ATM Ventilation to the vehicle interior
EGR Vacuum to the changeover valve ARF
VAC Vacuum from the vacuum pump
VCV Vacuum from the vacuum control valve
14.1621 7611 RA / 4
Page 5
Note
The control of the ARF valve or the These application delays are available
Pressure control valve by the control unit ARF After each motor start independent of the
(N37): Coolant temperature.
Exhaust gas return from approx. 100 seconds
After engine start
Pressure control valve from approx. 150 seconds
After engine start
Functional check
Preliminary step / Me device / Activity/ Setpoint Possible
Scope of delivery Connection requirement Cause / Remedy
ARF valve Vacuum tester Engine stopped ARF valve Replace ARF valve
At ARF Ventil directlyARF valve with Closes
Connect. 400 mbar Can be heard
beat.
Suppression
Remove.
Pressure control Vacuum tester Engine stopped Pressure control Pressure control valves

flap To vacuum can Vacuum can Flap Check housing
Pressure control valve With 400 mbar Selfemployed
Directly. To charge Back
Suppression
Remove.
Exhaust gas regulation
Vacuum tester Engine Control unit ARF (N37)
circle With Y Distribution 1250 50 / min 360 20 mbar
ARF Ventil an Vacuum control valve
Close (65)
Engine Pressure transducer (123) 1)
3400 50 / min 10 mbar
Changeover valve ARF
(Y27)
Vacuum supply
Vacuum tester Engine Control unit ARF (N37)

With Y Distribution 1300 50 / min 700 mbar
Vacuum can Changeover valve pressure
Pressure control valve Control valve (Y28)
Connect. 3400 50 / min 10 mbar
Vacuum supply
1) Only automatic transmission
RA 14.1621 7611 / 5
Page 6
Test program for individual parts testing
1) Druckum Vacuum tester Engine in the If the negative pressure is exceeded
Setters (123) With Y Distribution Neutral 360 20mbar Or below the setpoint,
And pressure EGR Connection of the Adjust the vacuum.
position Pressure transducer For this purpose protective cap ab
Close. Pull and Steck
Key insert (4mm)
Setting value: According to
360 5mbar Set the setting value.
Vacuum control valve
Supply pressure on
Check connections VAC,,
Possibly pressure converter er
New
Pressure line to
Check the functional scheme.
Supply pressure at the
Check vacuum pump
(RA motor 601, 602.91,
603.91, combustion I,
07.1 160).
Specification: 700 mbar.
Negative pressure A) automatic
Control valve Transmission
(65) Vacuum tester Engine in idle 350 mbar
With Y Distribution Run
Connections
Pressure transducer Motor switched off,
Regulation 10mbar Vacuum lines
(123).
Full load setting. According to function scheme
Test
B) mechanical
Transmission Supply suppression
Vacuum tester Test
With Y Distribution Engine in idle 300mbar Specification 700 mbar
Connect 2 of the Run
Changeover valve
(Y27) Motor switched off,
(Head connection Regulation 10mbar
perpendicular). Full load setting
RA 14.1621 7611 / 6
Page 7
Switchover Y27 Engine Control unit ARF (N37)
Tile (Y27, Y28) 1 2 1250 50 / min 11 14 V
Stress Starter speedometer
care 3400 50 / min 1 V Tooth ring (L3)
Test
Y28 Engine Connector
1 2 1300 50 / min 11 14 V Number of starter teeth
Crown (L3x1)
3400 50 / min 1 V
Protection (K1 / 2)
Changeover valve Vacuum tester Engine Vacuum control valve

ARF (Y27) With Y Distribution 1250 50 / min 300 mbar (65)
Pressure relief Connect 3 of the
Supply Changeover valve ARF Pressure transducer (123) 1)
Connect.
Supply suppression
Test
Changeover valve Vacuum tester Engine Supply suppression
Pressure With Y Distribution 1300 50 / min 700 mbar Test
Control valve Connect 3 of the
(Y28) Changeover valve
Pressure relief Pressure control valve
Supply Connect.
Speed transmitter Connector (L3), distance, dirt

Starter tooth Starter tooth
Crown (L3) Crown (L3x1) Line interruption
Deducted
tension
L3x1 Engine in the
1 2 Neutral 5V 2)
resistance L3x1 Engine stopped Beru: (L3), distance, dirt
1 2 530 3)
10% Line interruption
VDO:
1900 3)
10%
AB Electronics
1040 3)
10%
2) The voltage increases with increasing speed
3) Measured at 20 C ambient temperature (each 10 C modified ambient temperature, the resistance to 4%) changes
RA 14.1621 7611 / 7
Page 8
Microswitches X26 / 7 Motor switched off (S27 / 6)
(S27 / 6) 5 2 For both tests
6 2 Connections: cables
Accelerator pedal in
Idle position 1
Full load setting As shown in Fig
Compressor X26 / 7 Engine stopped (S27 / 6)

Disconnection 9 2 Accelerator pedal in
Idle position As shown in Figcables
Full load setting 1
RA 14.1621 7611 / 8
Page 9
B. Motor 606,910
Functional diagram Exhaust gas purification engine 606.910 with mechanical gearbox
P14 5148 57
5 flywheel B11 / 4 Temperature sensor Coolant,
10 Injection pump B11 / 8 Temperature sensor coolant, afterglow
12/1 Vacuum can stop L3 Speed transmitter
12/4 Vacuum box resonance N8 / 1 Control unit ELR / ARA
12/5 Vacuum box resonance pipe N14 Preheating relay
24 Accelerator pedal N22 Control and operating unit
65 Vacuum control valve Automatic climate control (KLA)
99/1 Resonance N37 / 3 Control unit ARF / Register Suction system
99/3 Resonance pipe S27 / 6 Microswitch compressor shutdown / ARF
101 Exhaust gas return valve Y22 Solenoid solenoid ELR
102 Vacuum box pressure control valve Y22 / 3 Positioning solenoid ARA
104 Vacuum pump Y22 / 6 Changeover valve resonance pipe
107 Exhaust manifold Y22 / 7 Reversing valve resonance
109 Pressure control valve housing Y27 Changeover valve ARF
Y28 Changeover valve Pressure control valve
A Ventilation
B Key lock
C
E To the brake
RA 14.1621 7611 / 9
Page 10
Functional diagram Exhaust gas purification engine 606.910 with automatic transmission
P14 5149 57
5 flywheel B11 / 4 Temperature sensor Coolant,
10 Injection pump B11 / 8 Temperature sensor coolant, afterglow
12/1 Vacuum can stop L3 Speed transmitter
12/4 Vacuum box resonance N8 Control unit ELR
12/5 Vacuum box resonance pipe N14 Preheating relay
24 Accelerator pedal N22 Control and operating unit
65 Vacuum control valve Automatic climate control (KLA)
99/1 Resonance N37 / 3 Control unit ARF / Register Suction system
99/3 Resonance pipe S27 / 6 Microswitch compressor shutdown / ARF
101 Exhaust gas return valve Y22 Solenoid solenoid ELR
102 Vacuum box pressure control valve Y22 / 6 Changeover valve resonance pipe
104 Vacuum pump Y22 / 7 Reversing valve resonance
106 Vacuum box Modeling pressure Y27 Changeover valve ARF
107 Exhaust manifold Y28 Changeover valve Pressure control valve
109 Pressure control valve housing
123 Pressure transducer A Ventilation
B Key lock
C
D To the vacuum can automatic transmission
E To the brake
Pressure and vacuum connections
Pressure transducer
ATM Ventilation to the vehicle interior
EGR Vacuum to the changeover valve ARF
VAC. *** "
Vacuum from the vacuum pump
VCV Vacuum from the vacuum control valve
14.1621 7611 RA / 10
Page 11
Test conditions From approx. 30 s after each engine start
Coolant temperature 65 80 C, perfect Exhaust gas return from approx. 50 C
Function of temperature sensor Coolant Coolant temperature
(B11 / 4). Pressure control valve from approx. 65 C
Coolant temperature
Note The drive delay time lags
The control of the individual parts by the Any engine start even if the coolant
Control unit ARF / Register Suction system Temperature when starting is greater than 65 C
(N37 / 3) is carried out under the following conditions: Is.
Functional check
Preliminary step /
Me device / Activity/ Setpoint Possible cause / remedy
Scope of delivery
Connection requirement
ARF valve Vacuum test Engine stopped ARF valve Replace ARF valve
Advises on ARF Ventil
ARF valve with Closes
Directly 400 mbar be Can be heard
Strike
Suppression
Remove
Pressure Vacuum test Engine stopped Pressure control Pressure control valves
Control valve Advise against negative pressure
Vacuum can Flap Check housing
Pressure control With 400 mbar Selfemployed
Close the valve directly
To charge Back
Close Suppression
Remove
Exhaust gas regulation
Vacuum test Engine 375 15 mbar Control unit ARF / Register
circle Advises with Y Distribution
1100 50 / min Suction system (N37 / 3)
At the ARF Ventil an 325 15 mbar
Close Changeover valve ARF (Y27)
Vacuum control valve (65)
3200 50 / min 10 mbar
From about 10/93: Pressure transducer (123) 1)
2850 50 / min
Vacuum supply
Vacuum test Engine Control unit ARF / Register

Advises with Y Distribution
1250 50 / min 700 mbar Suction system (N37 / 3)
To vacuum can
Pressure control valve Changeover valve pressure
Connect 2550 50 / min 10 mbar Control valve (Y28)
Vacuum supply
H hengeber B18 only
P1RB07.99.1699 7611 RA / 11
Page 12
Pressure Vacuum tester Engine in idle If the negative pressure is exceeded
setter (123) 1) With Y Distribution Run 375 15 mbar Or below the setpoint,
And pressure Input 2 of the Adjust the vacuum.
position Changeover valve 335 15 mbar For this purpose protective cap ab
(Y27). Pull and Steck
Key insert (4mm)
Setting value: According to
375 5 mbar Set the setting value.
335 5 mbar Vacuum control valve

(65)
Supply pressure on
Check connections VAC,,
Possibly pressure converter er
New
Vacuum line to
Check the functional scheme.
Supply pressure at the
Check vacuum pump
(RA motor 601, 602.91,
603.91, combustion I,
07.1 160).
Specification: 700 mbar.
Negative pressure A) automatic Engine in idle 350 mbar Vacuum lines

Control valve Transmission Run 300 mbar According to function scheme
(65) Vacuum tester Test
With Y Distribution Motor switched off,
Connections Regulation Supply suppression
Pressure transducer Full load setting. 10 mbar Test
(123) Specification 700 mbar
B) mechanical Engine in idle 350 mbar

Transmission Run Vacuum control valve
Vacuum tester (65)
With Y Distribution Motor switched off,
Connect 2 of the Regulation 10 mbar
Changeover valve (Y27)Full load setting
(Head)
Vertical).
14.1621 7611 RA / 12
Page 13
Switchover Y27 Engine Control unit ARF / Register
Tile (Y27, Y28) 1 2 1100 50 / min 11 14 V Suction System (N37 / 3)
Stress
care 3200 50 / min 1 V Control unit ELR / ARA
Test From about 10/93: (N8 / 1) or control unit
2850 50 / min ELR (N8)
Y28 Engine
1 2 1250 50 / min 11 14 V Protection, 9pole (K1 / 2)
2500 50 / min 1 V Starter speedometer

Tooth ring (L3)
Connector
Number of starter teeth
Crown (L3x1)
H hengeber B18 only
cables
Changeover valve Vacuum tester Engine at 370 15 mbar Vacuum control valve (65)
(Y27) With Y Distribution 1100 50 / min 325 15 mbar
Pressure relief Connect 3 of the Pressure transducer (123) 1)
Supply Changeover valves
(Y27). Supply suppression
3200 50 / min 10 mbar Test
From about 10/93:
2850 50 / min
Changeover valve Vacuum tester Engine Supply suppression
(Y28) With Y Distribution 1250 50 / min 700 mbar Test
Pressure relief Connect 3 of the
Supply Changeover valves 2500 50 / min 10 mbar
(Y28).
Speed transmitter Control unit Control unit ELR / ARA

Starter tooth (N37 / 3) (N8 / 1) or control unit
Crown (L3) Switched off ELR (N8)
Remove engine
tension
N37 / 2 Engine in the Protection, 9pole (K1 / 2)
11 2 Neutral 5V 2)
Plug connections motor
Cable set, 12pol. (X26 / 7)
(L3), distance, dirt
Connection speed
Geared starter ring
(L3x1)
cables
2) The voltage decreases with increasing speed
P1RB07.99.1699 7611 RA / 13
Page 14
resistance N8 N8 / 1 Engine stopped Beru: (L3), distance, dirt
10 12 Control unit 527 1)
(N8 N8 / 1) 10% Connector
Developed VDO: Payer Starterkranz
1900 1) (L3x1)
10%
AB Electronics cables
1040 1)
10%
cables N8 N8 / 1 L3x1 Engine stopped
10 2 Control unit 1
12 1 (N8 N8 / 1) out
Built
Connector
(L3x1)
Respectively
N37 / 3 N8 N8 / 1Control units
2 6 (N8 N8 / 1) and
(N37 / 3) 1
Building
Microswitches X26 / 7 Engine stopped Neutral (S27 / 6)
(S27 / 6) 2 5 Connector 1
2 6 (X26 / 7) Full load cables
Respectively As shown in Fig
Compressor X26 / 7 Engine stopped Neutral (S27 / 6)

Disconnection 2 11 Connector As shown in Fig
(X26 / 7) Full load cables
Respectively 1
Increasing B18 Connector B18

B18 only B18x1 (B18x1)
tension 1 Half peeled off 11 14V 2)
Engine
1250 50 / min
Resistance B18 Connector B18
2 1 (B18x1) 1 2)
Respectively
1)
Measured at 20 C ambient temperature (10 C of changed ambient temperature, the resistance changes
4%)
2) Measured 780 to 25 mbar air pressure.
Note
Control unit ARF / Register Adjust System
(N37 / 3) from about 10/93 onwards. To avoid
From Blaurauch Switchoff speed of the exhaust gas recirculation
Changed function. Control unit Part no .:
061 545 95 32 and 016 545 91 32, respectively.
P1RB07.99.1699 7611 RA / 14

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25/04/2017 14 7611 Checking exhaust gas recirculation

Functional check. . . . . . . . . . . . . . . . . . . . . . . Carry out. Motor 605.911 section a

603 589 00 21 00 201 589 13 21 00 201 589 00 99 00

Pressure control Vacuum tester Engine stopped Pressure control Pressure control valves

Vacuum tester Engine Control unit ARF (N37)

Changeover valve Vacuum tester Engine Vacuum control valve

Speed transmitter Connector (L3), distance, dirt

Compressor X26 / 7 Engine stopped (S27 / 6)

Vacuum test Engine Control unit ARF / Register

335 5 mbar Vacuum control valve

Negative pressure A) automatic Engine in idle 350 mbar Vacuum lines

B) mechanical Engine in idle 350 mbar

2500 50 / min 1 V Starter speedometer

Speed transmitter Control unit Control unit ELR / ARA

Compressor X26 / 7 Engine stopped Neutral (S27 / 6)

Increasing B18 Connector B18

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