Remove/install heat exchanger

AR18.30-G-6841DD

Remove/install heat exchanger

14.08.2019

Engine

900.91/92 in model 000.001

Engine

902.91/93 in model 000.001

Engine

904.94/95/96/97 in model 000.001

Engine

906.90/93/94/95/96/98/99 in model 000.001

Engine

924.91/93/94 in model 000.001

Engine

925.9 in model 000.001

Engine

926.91/92/93/95/97/98 in model 000.001

Shown on engine 926.9

1

Oil filter cover

2

O-ring

3

Oil filter element

4

Air intake hose

Shown on engine 926.9 up to engine end number 301561

5

Cover

9

Turbocharger

6

Seal

10

Control line

7

Heat exchanger

11

Oil pressure line

8

Electrical connector

13

Pressure and temperature sensor

Shown on engine 926.9 as of engine end number 301562

5

Cover

9

Turbocharger

10

Control line

11

Oil pressure line

12

Electrical connector

14

Engine oil temperature sensor

15

Oil pressure sensor

16

Electrical connector

 Danger

Risk of explosion due to escaping combustible gas or overheating of gas cylinders.Risk of injury caused by burns to skin and eyes. Risk of frostbite to body parts caused by escaping gas and by touching components near the valves when emptying gas cylinders. Risk of poisoning or suffocation caused by inhaling gas.

Remove any sources of ignition.
Protective clothing, safety gloves and safety glasses must always be worn.
Ensure that the work area is adequately ventilated.
When working on vehicles at ambient temperatures over 60 °C, all gas cylinders must be removed.

AS00.00-Z-0018-01A

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

Topical note

Information on working sealing surfaces when carrying out engine repairs

AH01.10-N-0002-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

Notes on work safety regulations for vehicles with natural gas-powered engines

AH00.10-N-1000-04A

 

Remove/install

1

Drain off coolant.

AR20.00-G-1142DD

 Collect escaping coolant using suitable vessel.

2

Remove air intake hose (4).

 Installation: Only install air intake hose (4) after filling the oil circuit.

3

Unscrew and remove oil filter cover (1).

 Upon unscrewing of the oil filter cover (1) the engine oil flows back into the oil pan.

 Installation: Replace O-ring (2) and check oil filter element (3) for damage and contamination.

 Oil filter cover to oil filter housing

*BA18.20-N-1003-01L

If oil filter element (3) is soiled or damaged



Replace oil filter element (3).

4

Remove bleed line.

Only for engine 900.9.

 Bolt, coolant pump connection piece to cylinder head

*BA20.10-N-1003-01L

5

Remove oil pressure line (11).

 Installation: Install new sealing rings.

 Collect engine oil which flows out in a suitable vessel.

 Close off oil pressure bore holes.

 Bolt, oil pressure line to turbocharger

*BA09.40-N-1002-01J

 Union nut, oil pressure line to turbocharger

*BA09.40-N-1006-01J

6

Remove control line (10) at exhaust gas turbocharger (9).

Only if control line (10) is installed.

7.1

Disconnect electrical connector (8) at pressure and temperature sensor (13).

For engine 902.9 Engine 904.9 as of engine end number 040488 to 301576 Engine 906.9 up to engine end number 301561 Engine 926.9 up to engine end number 301561.

7.2

Disconnect electrical connector (12) at engine oil temperature sensor (14) and electrical connector (16) at oil pressure sensor (15).

For engine 900.9 Engine 904.9 as of engine end number 301577 Engine 906.9 as of engine end number 301562 Engine 924.9 Engine 926.9 as of engine end number 301562.

8

Clean cylinder head in area of exhaust manifold.

9

Release exhaust manifold at cylinder head and push away.

Only for engine 904.9.


When unfastening exhaust manifold ensure that neither dirt nor foreign object can find their way into the exhaust manifold.
Exhaust gas turbocharger will otherwise be damaged.

 Unscrew screws by approx. 4 mm.

 Installation: Replace seals.

 Bolt, exhaust manifold to cylinder head

*BA14.10-N-1001-01K

10

Check shank length of exhaust manifold screws.

Only for engine 904.9.

 Unscrew screws individually for measurement purposes.

Screw, exhaust manifold

*BE14.10-N-1001-01B

If necessary,



Replace exhaust manifold screws.

11

Remove cover (5) with heat exchanger (7) from crankcase.

 Check heat exchanger (7) for damage, replace if necessary.
In the case of discernible material abrasion in engine oil, replace heat exchanger (7).

 Installation: Clean sealing surfaces and replace gasket.

 Bolt, heat exchanger to crankcase

*BA18.30-N-1001-01N

12

Remove heat exchanger (7) from cover (5).

 Installation: Clean sealing surfaces and replace seal (6).

 Bolt, housing cover to heat exchanger

*BA18.30-N-1002-01N

13

Remove screw plugs from cover (5).

Only in case of leak at screw plugs and/or when replacing cover (5).

 Install new sealing rings.

 Heat exchanger screw plug

*BA18.30-N-1003-01N

14

Remove engine oil temperature sensor (14) from cover (5).

Only for engine 926.9 as of engine end number 301562.
Only in case of leaks at engine oil temperature sensor (14) and/or when replacing cover (5).

 Installation: Install new sealing rings.

 Engine oil temperature sensor to heat exchanger

*BA18.40-N-1005-01I

15

Install in the reverse order



Check

16

Fill oil circuit.

AR18.00-G-1600DD

17

Start engine and run at idling speed.

 See information from body manufacturer.
The oil pressure must have built up no later than 10 s after the start.

If the oil pressure has not built up 10 seconds after the start,



Switch off the engine and determine the cause.

Engine oil pressure

*BE18.00-N-1001-01I

18

Allow engine to run at alternating engine speed, check heat exchanger (7) and oil pressure line (11) for leaks.

 Visual inspection.

19

Switch off engine.

Check values for exhaust manifold

Number

Designation

Engine 900.9, 902.9, 904.9, 906.9, 924.9, 925.9, 926.9 in model 000.001

BE14.10-N-1001-01B

Screw, exhaust manifold

Thread diameter

M

10

Length of shank when new

mm

47,0

Permissible shank length

mm

47,5

Test specifications for engine oil pressure

Number

Designation

Engine 900.9, 902.9, 904.9, 906.9

Engine 924.9, 925.9, 926.9 in model 000.001

BE18.00-N-1001-01I

Engine oil pressure

idle speed

bar

0,5

0,5

maximum speed

bar

2,5

2,5

 Turbocharger

Number

Designation

ENGINE 900.9, 904.9

ENGINE 902.9, 906.9

BA09.40-N-1002-01J

Bolt, oil pressure line to turbocharger

M8

Nm

40

40

M6

Nm

10

10

 Turbocharger

Number

Designation

Engine 924.9, 925.9, 926.9 in model 000.001

BA09.40-N-1002-01J

Bolt, oil pressure line to turbocharger

M8

Nm

40

M6

Nm

10

 Turbocharger

Number

Designation

ENGINE 900.9, 904.9

ENGINE 902.9, 906.9

BA09.40-N-1006-01J

Union nut, oil pressure line to turbocharger

M14

Nm

30

30

M16

Nm

35

35

 Turbocharger

Number

Designation

Engine 924.9, 925.9, 926.9 in model 000.001

BA09.40-N-1006-01J

Union nut, oil pressure line to turbocharger

M14

Nm

30

M16

Nm

35

 Exhaust manifold

Number

Designation

Engine 900.9, 902.9, 904.9, 906.9

BA14.10-N-1001-01K

Bolt, exhaust manifold to cylinder head

Stage 1

Nm

10

Stage 2

Nm

55

Stage 3

°

90

 Oil filter

Number

Designation

Engine 900.9, 902.9, 904.9, 906.9

Engine 924.9, 925.9, 926.9 in model 000.001

BA18.20-N-1003-01L

Oil filter cover to oil filter housing

Nm

25

25

 Oil cooling

Number

Designation

Engine 900.9, 902.9, 904.9, 906.9

Engine 924.9, 925.9, 926.9 in model 000.001

BA18.30-N-1001-01N

Bolt, heat exchanger to crankcase

Nm

25

25

 Oil cooling

Number

Designation

Engine 900.9, 902.9, 904.9, 906.9

Engine 924.9, 925.9, 926.9 in model 000.001

BA18.30-N-1002-01N

Bolt, housing cover to heat exchanger

Nm

25

25

 Oil cooling

Number

Designation

Engine 900.9, 902.9, 904.9, 906.9

Engine 924.9, 925.9, 926.9 in model 000.001

BA18.30-N-1003-01N

Heat exchanger screw plug

Nm

20

20

 Oil level/oil pressure sensor

Number

Designation

ENGINE 900.9, 902.9, 904.9, 906.9 (except 906.901/902)

Engine 924.9, 925.9, 926.9 in model 000.001

BA18.40-N-1005-01I

Engine oil temperature sensor to heat exchanger

Nm

45

45

 Coolant pump, coolant thermostat

Number

Designation

Engine 900.9, 902.9, 904.9, 906.9 in model 000.001

Engine 924.9, 925.9, 926.9 in model 000.001

BA20.10-N-1003-01L

Bolt, coolant pump connection piece to cylinder head

Nm

50

50