S20.20-4503-09
1 Air filter cross pipe
2 Vacuum pump
3 Clip
4 Charge air hose
5 Mixing chamber
6 Engine support
7 Coolant hose
8 Coolant pipe
16 Charge air hose
17 Bolt
18 Coolant hose
19 Clip
20 Locking plate
21 Shift cable
22 Bracket
9 Coolant hose
10 Bolt
11 Clip
12 Clip
13 Charge air hose
14 Charge air pipe
15 Clip
| 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. | |
1 | Drain coolant | ||
| |||
2 | Remove air filter housing | ||
3 | Remove air filter cross pipe (1) | ||
4 | Remove engine designer cover | ||
5 | Detach vacuum line at vacuum pump (2) | ||
6 | Unscrew clamp (3) on charge air hose (4) and remove charge air hose (4) from mixing chamber (5) | Expose charge air hose (4). | |
7 | Place a suitable base under the engine between oil pan and axle/engine subframe | Place base for 10 to 15 mm. | |
8 | Support engine with a vehicle jack on the oil pan | Use a rubber base in order to avoid damaging the oil pan. | |
9 | Unscrew bolt from engine support (6) on support plate | | |
10 | Unscrew bolts from engine support (6) on cylinder head | | |
External torx set | |||
11 | Remove engine support (6) above | ||
12 | Remove upper coolant hose (7) from coolant pipe (8). | ||
13 | Detach coolant hose (9) | ||
14 | Unscrew bolt (10). | External torx set | |
15 | Remove clamp (11) on bracket | External torx set | |
16 | Remove charge air hose (13) clamp (12) on charge air pipe (14) | ||
17 | Remove charge air hose (16) clamp (15) on charge air cooler | With code MQ3 (engine OM611 DE22A (60 kilowatt)) instead of charge air cooler on charge air pipe. | |
18 | Remove bolts (17) on charge air pipe (14) | ||
19 | Unscrew both brackets from front exhaust rubber holder | 4 bolts. | |
20 | Remove charge air pipe (14) | Thoroughly clean connection points of hose clamps otherwise the charge air hoses can be pinched during operation. | |
21 | Detach lower coolant hose (18) from coolant pipe (8). | ||
22 | Take off clamp (19) | External torx set | |
23 | Remove lock washer (20) on shift cables (21) and lead shift cable (21) out of the bracket (22) | With code G40 (automatic transmission), only one shift cable (21) available. | |
24 | Remove coolant pipe (8) | Do not damage sound dampening mat. | |
Remove coolant pipe (4) downwards. | |||
25 | Install in the reverse order | ||
| Checking | ||
26 | Inspect cooling system for leaks |
Oil pan
Number | Designation | Engine | ||
BA01.45-N-1001-01H | Bolt, oil pan to cylinder crankcase | M6 | Nm | 9 |
M8 | Nm | 20 | ||
M10 | Nm | - | ||
Radiator, radiator hoses, radiator lines
Number | Designation | Engine | |
BA20.20-N-1002-01G | Bolt, coolant pipe at cylinder head | Nm | 14 |
BA20.20-N-1003-01G | Bolt, coolant pipe mounting clamp to cylinder head bracket | Nm | 14 |
Engine mounts, engine supports
Number | Designation | Model 638 with engine 611.980 | ||
BA22.10-N-1001-01I | Bolt, engine support on the right to support plate | Nm | 180 | |
BA22.10-N-1002-01I | Bolt, engine support on the right to cylinder head | Stage 1 | Nm | 40 |
Stage 2 | ° | 45 | ||
Stage 3 | ° | 45 | ||
Stage 4 | ° | 45 | ||
External Torx set
001 589 76 09 00
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