Remove/install heat exchanger · ar1830g6841dd · Mercedes-Benz WIS

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

W18.30-1003-11

G18.30-3119-09

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

G18.30-3121-06

 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

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