Service News
	Copyright By FCA Italy S.p.A. - Printed 07/10/2013– Es.954

Cancels and replaces the SN 10.36.11 of 18.07.2012 for Part Availability table upgrade

FAULT COMPLAINED OF

Water leak from the exhaust gas/water heat exchanger for EGR system.

TECHNICAL CAUSE

Water leak from the plastic reservoir, housing the heater core, next to one of the three stiffening ribs.

OPERATIONS IN PRODUCTION

Installation of a new plastic reservoir, with improved features.

IPLEMENTATION OF MODIFICATION

OPERATIONS IN NETWORK

Network behaviour standards towards the Customer

• Once the customer's claimed fault is confirmed, reassure the Customer that the fault will be solved by replacing the plastic reservoir of the heat exchanger installed on the EGR module and the relevant seals.
• After the operation, show the Customer what has been done and make sure he is satisfied.

Service Solution

Once the claimed fault is found, only replace the plastic reservoir of the heat exchanger installed on the EGR module, with the relevant seals, according to the Operating Cycle below.

OPERATION CYCLE

Position the vehicle on the lift.

• Disconnect the electrical connection for the EGR heat exchanger water supply actuator control solenoid.
• Undo the five fixing screws (1 - Fig. 1) and remove the water/ exhaust gas heat exchanger for EGR system (2) with heater core and gaskets, with reference to Op. 1080C of the Service Manual.
• Working on bench, undo the two fixing screws (3 - Fig. 1), disconnect the vacuum intake pipe (4) and remove the solenoid valve (5), if available, complete with mounting bracket from the water/exhaust gas heat exchanger.

Fig. 1

1 - EGR solenoid valve bracket fixing screw

2 - EGR system heat exchanger

3 - Heat exchanger fixing screw

4 - EGR solenoid valve pipe

5 - EGR solenoid valve

Take from the Spare Parts Dpt. the kit to replace the reservoir for the EGR heat exchanger, as shown in Fig. 2.

Fig. 2

Kit composition

1 - Plastic reservoir of the heat exchanger

2 - Seal between reservoir and heat exchanger

3 - Seal between heat exchanger and EGR module

• Replace the reservoir for the EGR heat exchanger removed with a new one (1) available in the kit and make sure that the seal (2) is correctly fitted in its housing.
• Install the previously removed heat exchanger (3), proceeding in the order shown in Fig. 3.

Fig. 3

1 - Plastic reservoir of the heat exchanger

2 - Seal between reservoir and heat exchanger

3 - Heat exchanger

• Replace the seal (1 - Fig. 4) between heat exchanger and EGR module with the new seal, taken from the kit (re. 3 - Fig. 2), making sure that it is correctly fitted in its housing.

Fig. 4

1 - Seal between heat exchanger and EGR module

• Working on bench, install on the water/exhaust gas heat exchanger the solenoid valve with its mounting bracket, if available; tighten the two fixing screws previously removed and connect the vacuum intake pipe.
• Then install the complete heat exchanger unit on the EGR module and tighten the five fixing screws previously removed, in the order shown in fig. 5, tightening to the torque of 1 daNm.

Fig. 5

Reinstall the removed components, working in the reverse order of removal.

AVALABILITY OF PARTS

CLAIM REPORT DATA

(*) The time allowance includes draining and filling of engine coolant.