Remove/install oil-water heat exchanger

AR18.30-I-6840B

Remove/install oil-water heat exchanger

4.12.09

 

Remove/install

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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

1

Drain coolant

 Collect coolant



Replace coolant

AP20.00-I-2080B



Notes on coolant

AH20.00-N-2080-01A

2

Remove oil filter element (6.1)

 Removing the
oil filter element (6.1) causes engine oil to flow out of the oil filter housing (6). Inspect oil filter element (6.1) for damage and dirt; replace if necessary



Replace oil filter element

AP18.20-I-0100-04B



*BA18.20-N-1003-01B



*366589010700

3

Remove charge air pipe

From charge air cooler to charge air manifold.

AR09.41-I-1311C

4

Remove air intake hose (10)

5

Remove oil pressure line (7)

 Collect overflowing engine oil. Close off connector opening on turbocharger and on oil filter housing (6) each with suitable stop plugs.

 Installation: Install new sealing rings.
Before installation of oil pressure line (7), fill the turbocharger bearing housing through the oil inlet hole with engine oil. Rotate the turbocharger shaft by hand during this step so that the bearing points are provided with a film of oil.



*BA09.40-N-1006-01B

6

Drain engine oil at oil-water heat exchanger (1)

 Unscrew screw plug (12) to do this. Drain oil into a suitable container.

 Installation: Replace sealing ring.



*BA18.30-N-1003-01C

7

Remove exhaust manifold from cylinder head

 Installation: Clean flange to cylinder head and exhaust manifold, replace seals.

Measure shank length of bolts. If the maximum shank length was exceeded the bolt involved is to be replaced.

*BE14.10-N-1001-01A



*BA14.10-N-1001-01B

8

Remove oil-water heat exchanger (1) at crankcase

 Collect coolant and engine oil that flows out.



*BA18.30-N-1001-01C



*BA18.30-N-1002-01C

9

Take off gasket (2)
at oil-water heat exchanger (1)

 Install: Replace gasket (2).

10

Take off housing cover (1.2) at heat exchanger (1.3)

 Installation: Only tighten bolt (1.1) after installing the oil/water heat exchanger (1) on the crankcase.

11

Take gasket (1.4) out of housing cover
(1.2)

 Installation: Replace seal (1.4).

12

Install in the reverse order

13

Fill engine oil circuit

AR18.00-I-1600B

Number

Designation

Engine
900.9, 902.9, 904.9, 906.9

BE14.10-N-1001-01A

Exhaust manifold bolts

Thread diameter

M

10

Shank length
when new

mm

47.0

Permissible shank length

mm

47.5

Number

Designation

Engine
900.9, 904.9

BA09.40-N-1006-01B

Union nut, oil pressure line to turbocharger

M14

Nm

30

M16

Nm

35

Number

Designation

Engine
900.9, 902.9, 904.9, 906.9

BA14.10-N-1001-01B

Bolt, exhaust manifold to cylinder head

Stage 1

Nm

10

Stage 2

Nm

55

Stage 3

°

90

Number

Designation

Engine
900.9, 902.9, 904.9, 906.9

BA18.20-N-1003-01B

Oil filter cover to oil filter housing

Nm

25

Number

Designation

Engine
900.9, 902.9, 904.9, 906.9

BA18.30-N-1001-01C

Bolt, oil-water heat exchanger to crankcase

Nm

25

BA18.30-N-1002-01C

Bolt, housing cover to oil-water heat exchanger

Nm

25

BA18.30-N-1003-01C

Screw plug for oil-water heat exchanger

Nm

20