Install component parts for conversion of vehicle to code O2I

SM20.00-W-0009-01WR

Install component parts for conversion of vehicle to code O2I

Engine

471.9 in model 963, 964

with code B3H (Water-type secondary retarder)

Only for vehicles with front coolant expansion reservoir

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

8.8

10.9

BA00.10-N-1003-01A

M8

Galvanized

Nm

23

32

Phosphated

Nm

21

29

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

12.9

BA00.10-N-1003-01A

M8

Galvanized

Nm

38

Phosphated

Nm

36

 Exhaust gas recirculation

Number

Designation

Engine 471.9

BA14.20-N-1010-01I

Banjo bolt, coolant line to exhaust gas recirculation cooler

M14x1.5

Nm

35

 Exhaust gas recirculation

Number

Designation

Engine 471.9

BA14.20-N-1025-01I

Screw/bolt, coolant pipe to coolant distributor

Nm

30

 Engine cooling, general

Number

Designation

Engine 471.9

BA20.00-N-1014-02D

Connection fitting M24x1.5 to coolant distributor

Nm

55

 Retarder

Number

Designation

MODEL 963, 964 with CODE B3H (Secondary water retarder)

BA43.30-N-1033-01F

Bolt/nut, cap to transmission

Nm

160

Repair materials

Number

Designation

Order number

BR00.45-Z-1010-06A

Lubricant, rubber assembly 1 l

A 000 989 03 67

1

Clean sealing surface on coolant distributor (1).

2

Attach new cover (2) with new seal and holder (3) to coolant distributor (1)   .

3

Attach coolant line (5) with new sealing rings to coolant distributor (1)   .

4

Attach holder (4) of coolant line (5) to holder (3)   .

 Install coolant line (5) and holder (4) free of tension.
If the coolant line (5) is installed under tension, the coolant line (5) will rupture during operation of the engine.

5

Clean sealing surface on cylinder head.

6

Screw new connection fitting into new coolant distributor (6)   .

 Moisten the O-ring of the new connection fitting with coolant before installation.

7

Attach new coolant distributor (6) with new seal (7) to cylinder head   .

8

Check sealing rings (10) in coolant hoses (8, 9); replace sealing rings (10) and coolant hoses (8, 9) if necessary.

9

Coat sealing rings (10) with lubricant.

10

Attach coolant hoses (8, 9) to coolant distributor (6).

 The safety clips (11) on the coolant hoses (8, 9) must be engaged.

11

Remove locking pressure line (return) (12) of retarder with holder (12.1).

 The locking pressure line (return) (12) and the holder (12.1) are no longer required.

12

Insert fitting (13) into coolant line (14).

13

Secure fitting (13) to coolant line (14) using clamp (16).

14

Seal fitting (13) with plug (17).

15

Secure coolant line (14) to wiring harness using cable ties (15).

16

Seal rear openings on plug (19) using stop plugs (19.1).

17

Seal electrical wiring harness (18) of retarder with plug (19).

18

Secure electrical wiring harness (18) of retarder to wiring harness (21) using cable ties (20).

19

Expose compressed-air supply line (22) of retarder.

20

Remove compressed-air supply line (22) from holder (23).

 Depending on the vehicle equipment, the compressed-air supply line (22) may be secured at a different position on the holder (23).

21

Remove compressed-air supply line of retarder (22).

 The compressed-air supply line of the retarder (22) is no longer required.

22

Check O-rings (24) of individual fasteners of compressed-air lines (25); replace fasteners of compressed-air lines (25) if necessary.

23

Secure compressed-air lines (25) to holder (23) again.

24

Clean sealing surface on transmission.

25

Place new O-ring (27) on new cap (26) free of twists.

26

Place new cap (26) with new O-ring (27) onto transmission (28).

27

Screw new cap (26) securely onto transmission using previous screws (29) and new screws (30)   .

 The replacement part number of the new screws (30) can be found in the ordering note.