ar0716p1100pp

Remove/install fuel cooler

Type ar · topic 07.16 · version 0107 · 2019-01-30

Applies to: Engine 611.962 in model 203.004/006/204/206/706 Engine 612.962 in model 203.016/216 Engine 612.967 in model 209.316

Where it sits

Function group 1 Engine › 07 Mixture formation › 07.16 Diesel injection system common rail — Series 203 (models 004, 006, 016, 204, 206, 216, 706) · Series 209 (models 316) · Series 611 (models 962)

EinPAS 16 Fuel/power supply to engine › 16.10 Fuel supply › 16.10.60 Preheating/cooling — Series 203 (models 004, 006, 016, 204, 206, 216, 706) · Series 209 (models 316) · Series 611 (models 962)

Also applies to engines/gearboxes: 612 962, 612 967

AR07.16-P-1100PP

Remove/install fuel cooler

04.12.2018

Engine

611.962 in model 203.004/006/204/206/706

Engine

612.962 in model 203.016/216

Engine

612.967 in model 209.316

Remove/install fuel cooler

1

Fuel return hose

2

Fuel supply hose

3

Coolant feed hose

4

Coolant return flow hose

5

Fuel cooler

7

Fuel cooler screws/bolts

P07.16-2298-12

Remove/install

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

Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1

Remove cylinder head cover trim

AR01.20-P-5014-02B

Screw/bolt, trim panel of cylinder head cover to cylinder head cover

*BA01.20-P-1002-01A

Screw/bolt, charge air distribution pipe cover to charge air manifold

*BA01.20-P-1003-01A

2

Disconnect fuel return hose (1) to fuel tank from the fuel cooler (5)

Clamp

*000589543700

3

Disconnect fuel supply hose (2) from rail from the fuel cooler (5)

Clamp

*000589543700

4

Disconnect coolant return flow hose (4) to thermostat housing

Clamp

*000589543700

5

Remove screws/bolts (7) at fuel cooler

Bolt, fuel cooler to charge air manifold

*BA07.16-P-1001-02A

6

Disconnect coolant feed hose (3) to fuel cooler

Lift fuel cooler.

Clamp

*000589543700

7

Install in the reverse order

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

8

Check cooling system for leaktightness

AR20.00-P-1010P

Notes on coolant level

AH20.00-P-1142-01CW

9

Check fuel system for leaks with engine running

Crankcase ventilation, cylinder head cover

Number

Designation

Engine 611.960/961/962

Engine 612.961/962/967

BA01.20-P-1002-01A

Screw/bolt, trim panel of cylinder head cover to cylinder head cover

Nm

10

10

Crankcase ventilation, cylinder head cover

Number

Designation

Engine 611.960/961/962

Engine 612.961/962/967

BA01.20-P-1003-01A

Screw/bolt, charge air distribution pipe cover to charge air manifold

Nm

10

10

Fuel cooling system

Number

Designation

Engine 611.962

Engine 612.962/967

BA07.16-P-1001-02A

Bolt, fuel cooler to charge air manifold

Nm

14

14

Remove/install fuel cooler

000 589 54 37 00

Clamp

Referenced documents