Mahindra Thar CRDe - EGR Cooler and EGR Pipe Removal

Repair Manual MAN-00190
THAR CRDe BS-IV MAY 2012/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2012 Mahindra & Mahindra Ltd.
 EGR Cooler and EGR Pipe Removal
 Use recommended rust free solution if EGR pipe mounting bolts are found jam.
 Replace gasket while assembling g EGR pipe (TC to EGR Valve).
 Check and top up the coolant level in radiator & reservoir.
 EGR Cooler is only applicable for BS-IV engines.
Nut/ Bolt description Quantity Nos. Spanner Size Torque Value – Nm.
EGR pipe mtg. bracket bolt.
EGR pipe mtg. allen bolt (exh side)
EGR pipe mtg. on valve body
EGR valve body on intake manifold
01
02
02
04
12 mm.
05 mm.
12 mm.
12 mm
25 ± 03
25 ± 03
25 ± 03
25 ± 03
Removal Steps – Refer illustration shown.
1. Remove NVH cover & intercooler assy.
2. Remove intake hose on manifold.
3. Remove EGR pipe mtg. brackets.
4. Remove EGR Pipe assembly from exhaust and intake manifold side.
5. Remove hoses on EGR cooler.
6. Remove EGR valve & cooler assembly.
7. Remove EGR gasket on intake manifold.
Assembly Procedure – Refer illustration shown.
1. Refit new EGR gasket.
2. Refit EGR valve assembly on intake manifold.
3. Refit EGR cooler & Pipe along with new gaskets.
4. Refit EGR pipe mtg. brackets on engine.
5. Reconnect intake hose and EGR cooler hoses.
6. Refit intercooler & NVH barrier assembly.
7. Check & insure for no leak of exhaust gas from system.
EGR COOLER AND PIPE REMOVAL
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