Remove/install oil separator

AR01.20-D-9750TSC

Remove/install oil separator

06.03.2020

Engine

274 in model 907

1

Cable duct

2

Bolts

3

Electrical wiring harnesses

4

Electrical connector

5

Shielding

6

Screw

7

Bolts

8

Oil separator

9

Bracket

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 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

 Danger

Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure

Keep all ignition sources out of hazard area.
Do not carry out any work on system when it is pressurized.

AS07.16-Z-0001-01A

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 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

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

Notes on carrying out repair work in the vehicle interior

AH68.00-N-0001-01S

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

General information on work on gasoline direct injection system

AH07.00-P-2000-01A



Remove

1

Clamp off ground line of on-board electrical system battery (G1).

AR54.10-D-0029TS

2

Remove cover of cylinder head cover.

AR01.20-D-5015TSC

3

Unscrew bolts (2).

4

Remove electrical wiring harnesses (3).

5

Release and disconnect electrical connectors of the ignition coils.

AR15.12-D-2003TSC

6

Lift cable duct (1) slightly and release and disconnect electrical connectors of the fuel injectors (Y62).

AR07.03-D-0004TSC

7

Release and disconnect electrical connector(4).

8

Remove screws of the shielding (5) in reverse order of the tightening procedure and remove shielding (5).

AR07.02-S-0815-01EG

9

Remove fuel pressure via the service connection.

AR07.03-S-1460-04EG

 Dust protection cap to service connection

*BA07.03-N-1001-01H

 Pressure hose

*119589046300

10

Remove high-pressure line and seal exposed connections with suitable stop plugs.

 Collect escaping fuel using suitable means.

 Record plug

*129589009100

11

Raise vehicle.

AR00.60-D-1000-04TS

Topical note

Special instructions for lifting and supporting vehicle

AH00.60-N-0100-01TS

12

Unscrew screw/bolt (6).

13

Unclip oil separator (8) from the bracket (9) and remove from the crankcase.

14

Lower vehicle.

15

Lift cable duct (1) and remove screws (7).

16

Remove oil separator (8) completely.



Clean

17

Clean sealing surfaces.

Assembly cleaner

*BR00.45-Z-1028-04A



Install

18

Install oil separator (8).

 Ensure correct installation position.
Replace seal.

19

Lift cable duct (1) and tighten screws (7).

 Screw/bolt, oil separator to cylinder head cover

*BA01.20-N-1005-01W

20

Raise vehicle.

21

Install oil separator (8) in the crankcase and tighten screw (6).

 Replace seal.

 Bolt, crankcase ventilation bleed line to crankcase

*BA01.20-N-1003-01W

22

Lower vehicle.

23

Install high-pressure line.

AR07.03-S-1010-02EG

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


Do not kink or bend high-pressure lines.
This prevents leaks or damage.

 Union nut, high-pressure line to rail

*BA07.03-N-1002-01H

 Union nut, high-pressure line to high pressure pump

*BA07.03-N-1003-01H

 Tool kit

*000589109900

24

Install shielding (5) and tighten screws as per tightening procedure.

AR07.02-S-0815-01EG

 Bolt for high-pressure pump shielding

*BA07.02-N-1002-01F

25

Connect electrical connector (4).

26

Lift cable duct (1) slightly and connect electrical connectors of the fuel injectors (Y62).

AR07.03-D-0004TSC

27

Connect electrical connectors of the ignition coils.

AR15.12-D-2003TSC

28

Check retaining clamps and attach electrical wiring harnesses (3).

If retaining clips are damaged,



Replace retaining clips.

29

Tighten screws (2).

 M6

*BA00.10-N-1002-01A

30

Install cover of cylinder head cover.

AR01.20-D-5015TSC

31

Clip on ground line of the on-board electrical system battery (G1).

AR54.10-D-0029TS



Check

32

Check fuel high-pressure circuit.

AR07.03-S-1010-04EG

33

Check engine oil level, correct if necessary.



AP18.00-D-0101TSC

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-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

34

Perform engine test run; while doing so, check engine, fuel system, and oil separator (8) for leak tightness.

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

Number

Designation

8.8

10.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

9

13

Phosphated

Nm

9

12

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

Number

Designation

12.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

16

Phosphated

Nm

14

 Crankcase ventilation, cylinder head cover

Number

Designation

Engine 274

BA01.20-N-1003-01W

Bolt, crankcase ventilation bleed line to crankcase

Nm

9

 Crankcase ventilation, cylinder head cover

Number

Designation

Engine 274

BA01.20-N-1005-01W

Screw/bolt, oil separator to cylinder head cover

Nm

9

 High pressure pump

Number

Designation

Engine 274 in model 907

BA07.02-N-1002-01F

Bolt for high-pressure pump shielding

Nm

20

 Injection nozzles, injection valves, lines

Number

Designation

Engine 274 in model 907

BA07.03-N-1001-01H

Dust protection cap to service connection

Plastic

Nm

2

Metal

Nm

15

 Injection nozzles, injection valves, lines

Number

Designation

Engine 274 in model 907

BA07.03-N-1002-01H

Union nut, high-pressure line to rail

Stage 1

Nm

15

Stage 2

°

75

Stage 3

°

25

 Injection nozzles, injection valves, lines

Number

Designation

Engine 274 in model 907

BA07.03-N-1003-01H

Union nut, high-pressure line to high pressure pump

Stage 1

Nm

15

Stage 2

°

75

Stage 3

°

25

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01