Remove/install oil-water heat exchanger

AR18.30-D-6840D

Remove/install oil-water heat exchanger

15.2.12

8.7.08

Value altered: bolt, coolant pump connection piece to cylinder head

*BA20.10-N-1003-01C

 

Remove/install

1

Switch off ignition

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

2

Disconnecting the battery



Notes on battery

All models

AH54.10-P-0001-01A

3

Remove service cover

 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.

AS20.00-Z-0001-01A

4

Drain coolant

Collect coolant

AP20.00-D-2080A



Notes on coolant

All engines

AH20.00-N-2080-01A

5

Take off shield (9) at exhaust manifold

AR14.10-L-3915-02A



*BA09.41-N-1009-01B

Hand riveter

6

Detach shield (11) at turbocharger

 Facilitates removal and installation.



*BA09.40-N-1004-01B

7

Remove air intake hose

AR09.10-D-8030D

8

Remove oil filter housing

AR18.20-D-3471D

9

Detach oil pressure line (6) at turbocharger



*BA09.40-N-1002-01B

10

Unscrew bolt (8)



*BA20.10-N-1003-01C

11

Remove crankcase ventilation line (7) at oil separator

12

Remove screw plug (4) at oil-water heat exchanger (1) and drain engine oil

 Collect engine oil.

 Installation: Install new sealing ring (5).



*BA18.30-N-1003-01C

13

Unscrew exhaust manifold bolts about 4 mm and push exhaust manifold away from cylinder head

 Installation: Check gaskets for damage, if necessary

AR14.10-D-3915D

Remove exhaust manifold and replace gaskets.

14

Take off oil-water heat exchanger (1) at crankcase

 Collect coolant and engine oil which flow out.

AR18.30-D-6840-01D



*BA18.30-N-1001-01C

15

Disassemble oil-water heat exchanger (1)

 Installation: If possible, do not tighten bolt (1.1) fully until after fitting on oil-water heat exchanger (1).

AR18.30-D-6840-02D



*BA18.30-N-1002-01C

16

Install in the reverse order

17

Check and correct coolant level

AP20.00-D-2080A

18

Fill engine oil circuit

AR18.00-W-1600A

Number

Designation

Engine
900.9, 904.9

BA09.40-N-1002-01B

Bolt, oil pressure line to turbocharger

M8

Nm

40

M6

Nm

10

BA09.40-N-1004-01B

Bolt, shield to turbocharger

Nm

25

Number

Designation

Engine
904.9 in model 668, 670

BA09.41-N-1009-01B

Bolt, shield to charge air manifold

Nm

25

Number

Designation

Engines
900.9, 902.9, 904.9, 906.9

BA18.30-N-1001-01C

Bolt, oil-water heat exchanger to crankcase

Nm

25

BA18.30-N-1002-01C

Bolt, housing cover to oil-water heat exchanger

Nm

25

BA18.30-N-1003-01C

Screw plug for oil-water heat exchanger

Nm

20

Number

Designation

Engines
900.9, 902.9, 904.9, 906.9

BA20.10-N-1003-01C

Bolt, connection piece of coolant pump to cylinder head

Nm

50